Robotic shuttle system

ABSTRACT

A robotic shuttle system includes a rack system and one or more shuttles. The rack system includes a rack and a shuttle frame. The rack has storage locations for containers containing items. The shuttle frame has rails disposed along the rack. The shuttle includes a powertrain, container transfer mechanism, and a robot arm. The power train is configured to move the shuttle along the rails of the rack and on a surface outside of the rack system. The container transfer mechanism is configured to transfer the containers between the rack and the shuttle. The robot arm extends from the shuttle to transfer the items between one of the containers on the shuttle and a container in a container holder of the shuttle.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication No. 62/645,459, filed on Mar. 20, 2018, which is herebyincorporated by reference.

BACKGROUND

With recent developments in electronic commerce, both in consumer andcommercial sectors, there has been a substantial increase in demand for“Mixed Stock Keeping Unit (SKU) Pallets” or mixed SKU orders in which asingle pallet or order requires multiple different kinds of SKUs. Forexample, grocery stores, convenience stores, and/or liquor stores maynot require an entire pallet of a particular brand of soft drink butinstead may require a mixed pallet containing different soft drinkbrands or other items. Consumers rarely order items in bulk such thattheir order typically contains a mix of SKUs. Processing mixed palletsor orders typically slows order fulfillment cycle times for shipping.These slow cycle times for both warehousing and shipping impact customerservice levels as well as manufacturing efficiencies. The quicker thatgoods can be processed and loaded onto trucks, trains, ships, airplanes,drones, or other vehicles, the larger geographical area a distributioncenter, manufacturing plant, or warehouse can service. For example, thequicker a truck can be loaded and unloaded, the more time is availablefor transporting items. A distribution center is then able to service alarger area because the truck can cover a greater distance in the sameamount of time. Thus, there is a need for improvement in this field.

Thus, there is a need for improvement in this field.

SUMMARY

A shuttle system includes one or more racks upon which SKUs are stored,a shuttle frame positioned proximal to the rack, and one or moreshuttles that are configured to service the racks by travelling alongthe shuttle frame. This shuttle system creates a robots-to-goodsenvironment in which the robotic shuttles automatically pick, place,and/or otherwise handle the goods. This robots-to-goods environmentcreated by the shuttle system is a significant improvement over thetraditional goods-to-person environment in which humans handle the goodswhich can be labor intensive and quite expensive. In this shuttlesystem, multiple shuttles form a swarm with each one operating inparallel with one another. Some or all of the shuttles in one variationhave independent missions, and in other variations, some or all of theshuttles can coordinate their activities so as to cooperate goodshandling missions. Various combinations of these approaches can be used.

In one example, each shuttle includes at least one robotic arm that isable to pick or place SKUs into totes that are carried on the shuttle.In one particular form, the robotic arm is a six-axis robotic arm, butother types of robotic arms can be used in other examples. In oneversion, the shuttle carries a tote in which SKUs are picked or placed.The shuttle further includes one or more extendable belt conveyors thatare able to extend into the racks to remove or load trays (or totes)stored in the rack. Once the tray is loaded onto the shuttle, therobotic arm is able to remove SKUs from the tray and place them into thetote on the shuttle (and vice-versa). The shuttle has the ability toguide itself so as to move independently of the rack system as well asdrive itself to the rack system so that it is able to service areas inthe warehouse outside of the rack. This is especially useful formicro-fulfillment situations such as for local pharmacies. The wheels onthe shuttles include independent electric motors that are able to rotateat least ninety degrees (90°) relative to the shuttle so as to steer theshuttle wheels when riding on the shuttle frame as well as outside ofthe racks.

The robotic arm includes a unique End of Arm Tool (EoAT) formanipulating SKUs. The EoAT includes a combination of a shark fingripper with strategically placed vacuum cups. In particular, the EoATincludes three shark fin gripping members, an extendable palm vacuumcup, fingertip vacuum cups placed at the ends of the shark fin grippingmembers, and inside finger digit vacuum cups. This unique combinationallows the EoAT to pick a wide variety of items both large and small aswell as those that are difficult to handle. In particular, the systemallows individual products to be picked up via the shark fin grippingmembers, a vacuum pickup followed by using the gripping members, asingle gripping option where the finger tips on the ends of the sharkfins are used alone, a multi-tip configuration in which the vacuum cupsat the end of the tips are brought closer together and all of them areused to pick up the individual products, and a single finger adjacentpicking up using the inside. Of course, there other ways in which theEoAT can pick or manipulate items. While the illustrated exampleincludes three shark fin gripping members, other examples can includemore or less of them.

The trays and/or totes incorporate a unique separator structure forinternally organizing SKUs. In one example, the separator structureincludes one or more monolayer webs that stretch at the opening and/orinside the trays and/or totes. In one form, the monolayer web includes agrid of elastic bands that form SKU openings where SKUs are stored. Withthe separator structure, a shuttle robot arm is able to perform blindpicks or puts without the need of a vision system. In one variation, theweb includes an X-Y array of rubber or elastic bands that help separatethe SKUs. The web also allows multiple different SKUs to be storedwithin the same tray and/or tote which in turn maximizes tote/trayutilization. With this configuration, the tote and/or tray can always betopped off to maximize packing density of stored SKUs. In othervariations, the web allows a single type of SKU to be stored in auniform array so as to provide high packing density. The uniform packingarray facilitates blind picking/putting which is typically faster thanpicking/putting with a vision system, but in other examples, visionsystems can be used. With the flexibility of the web, SKUs (either thesame or different) can be packed in a random storage pattern within thetray and/or tote. For instance, the flexibility of the web allowsdifferent sized and/or shaped SKUs to be packed within the same toteand/or tray. In some case, when packed in a random pattern, the roboticarm uses a vision system to pick or place SKUs.

Aspect 1 generally concerns a system that includes a shuttle with arobot arm that picks or places items in racks.

Aspect 2 generally concerns the system of aspect 1 in which the racksystem includes a shuttle frame where the shuttle travels along theracks.

Aspect 3 generally concerns the system of aspect 2 in which the shuttleis configured to move independently outside of the rack system.

Aspect 4 generally concerns the system of aspect 3 in which the shuttleincludes one or more steerable wheels that are powered by the shuttle.

Aspect 5 generally concerns the system of aspect 4 in which the wheelseach include a pinion and a drive wheel.

Aspect 6 generally concerns the system of aspect 5 in which the shuttleframe includes a vertical elevator rail with teeth configured to engagethe pinion.

Aspect 7 generally concerns the system of aspect 6 in which the shuttleswitch is configured to change movement of the shuttle between verticaland horizontal movement.

Aspect 8 generally concerns the system of aspect 7 in which the shuttleswitch includes a turntable with a straight track located betweenopposing curved tracks.

Aspect 9 generally concerns the system of aspect 5 in which the shuttleframe includes an intersection where the shuttle turns horizontally withthe wheels.

Aspect 10 generally concerns the system of aspect 9 in which theintersection includes one or more rail channels with turn shoulders inwhich the drive wheel is received.

Aspect 11 generally concerns the system of aspect 4 in which the shuttleincludes an Energy Storage System (ESS).

Aspect 12 generally concerns the system of aspect 11 in which the wheelsare configured to form an electrical circuit with rails to charge theESS.

Aspect 13 generally concerns the system of aspect 1 in which the shuttlehas a container holder and a rack container platform.

Aspect 14 generally concerns the system of aspect 13 in which the rackcontainer platform has a lift mechanism configured to move the rackcontainer platform vertically.

Aspect 15 generally concerns the system of aspect 14 in which the rackcontainer platform has an extendable conveyor configured to extend to anextended position in the racks.

Aspect 16 generally concerns the system of aspect 1 in which the shuttleincludes an extendable belt conveyor configured to extend to an extendedposition.

Aspect 17 generally concerns the system of aspect 1 in which the shuttleincludes a lift mechanism configured to vertically move a rack containerplatform.

Aspect 18 generally concerns the system of aspect 17 in which the liftmechanism is configured to raise the rack container platform above theshuttle.

Aspect 19 generally concerns the system of aspect 17 in which the liftmechanism is configured to lower the rack container platform below theshuttle.

Aspect 20 generally concerns the system of aspect 17 in which the liftmechanism is configured to move the rack container platform above andbelow the shuttle.

Aspect 21 generally concerns the system of aspect 1 in which the robotarm includes an End of Arm Tool (EoAT) with a shark fin finger to gripthe items.

Aspect 22 generally concerns the system of aspect 21 in which the sharkfin finger includes a tip vacuum cup.

Aspect 23 generally concerns the system of aspect 21 in which the sharkfin finger includes a grip pad with one or more vacuum ports.

Aspect 24 generally concerns the system of aspect 21 in which the EoATincludes an extendable palm vacuum cup that is configured to extend fromthe EoAT.

Aspect 25 generally concerns the system of aspect 1 in which the totewith an internal separator is supported on the shuttle.

Aspect 26 generally concerns the system of aspect 25 in which theinternal separator includes a monolayer web configured to separate theitems.

Aspect 27 generally concerns the system of aspect 26 in which themonolayer web includes a grid of elastic bands.

Aspect 28 generally concerns the system of aspect 27 in which the gridhas a perpendicular array of the elastic bands to separate the items.

Aspect 29 generally concerns the system of aspect 25 in which theshuttle is configured to map the position of the items in the tote forblind picking.

Aspect 30 generally concerns the system of aspect 25 in which the toteis configured to store multiple different kinds of Stock Keeping Units(SKUs).

Aspect 31 generally concerns the system of aspect 25 in which theinternal separator is configured to hold a uniform array of the itemswith the same Stock Keeping Unit (SKU).

Aspect 32 generally concerns the system of aspect 25 in which theshuttle includes a vision system for picking dense random storage of theitems in the tote.

Aspect 33 generally concerns the system of aspect 1 in which the racksystem includes an elevator with an elevator platform configured tovertically move the shuttle.

Aspect 34 generally concerns the system of aspect 33 in which theelevator platform includes one or more rails that support the shuttle.

Aspect 35 generally concerns the system of aspect 34 in which the railshave a ramped section that is tapered for loading the shuttle onto theelevator platform.

Aspect 36 generally concerns the system of aspect 33 in which theelevator platform includes one or more retention brackets configured toretain the shuttle during movement.

Aspect 37 generally concerns the system of aspect 33 in which theelevator includes a mezzanine entrance to transfer the shuttle to amezzanine.

Aspect 38 generally concerns the system of any previous aspect in whichthe rack system includes a shuttle frame where the shuttle travels alongthe racks.

Aspect 39 generally concerns the system of any previous aspect in whichthe shuttle is configured to move independently outside of the racksystem.

Aspect 40 generally concerns the system of any previous aspect in whichthe shuttle includes one or more steerable wheels that are powered bythe shuttle.

Aspect 41 generally concerns the system of any previous aspect in whichthe wheels each include a pinion and a drive wheel.

Aspect 42 generally concerns the system of any previous aspect in whichthe shuttle frame includes a vertical elevator rail with teethconfigured to engage the pinion.

Aspect 43 generally concerns the system of any previous aspect in whichthe shuttle switch configured to change movement of the shuttle betweenvertical and horizontal movement.

Aspect 44 generally concerns the system of any previous aspect in whichthe shuttle switch includes a turntable with a straight track locatedbetween opposing curved tracks.

Aspect 45 generally concerns the system of any previous aspect in whichthe shuttle frame includes an intersection where the shuttle turnshorizontally with the wheels.

Aspect 46 generally concerns the system of any previous aspect in whichthe intersection includes one or more rail channels with turn shouldersin which the drive wheel is received.

Aspect 47 generally concerns the system of any previous aspect in whichthe shuttle includes an Energy Storage System (ESS).

Aspect 48 generally concerns the system of any previous aspect in whichthe wheels are configured to form an electrical circuit with rails tocharge the ESS.

Aspect 49 generally concerns the system of any previous aspect in whichthe shuttle has a container holder and a rack container platform.

Aspect 50 generally concerns the system of any previous aspect in whichthe rack container platform has a lift mechanism configured to move therack container platform vertically.

Aspect 51 generally concerns the system of any previous aspect in whichthe rack container platform has an extendable conveyor configured toextend to an extended position in the racks.

Aspect 52 generally concerns the system of any previous aspect in whichthe shuttle includes an extendable belt conveyor configured to extend toan extended position.

Aspect 53 generally concerns the system of any previous aspect in whichthe shuttle includes a lift mechanism configured to vertically move arack container platform.

Aspect 54 generally concerns the system of any previous aspect in whichthe lift mechanism is configured to raise the rack container platformabove the shuttle.

Aspect 55 generally concerns the system of any previous aspect in whichthe lift mechanism is configured to lower the rack container platformbelow the shuttle.

Aspect 56 generally concerns the system of any previous aspect in whichthe lift mechanism is configured to move the rack container platformabove and below the shuttle.

Aspect 57 generally concerns the system of any previous aspect in whichthe robot arm includes an End of Arm Tool (EoAT) with a shark fin fingerto grip the items.

Aspect 58 generally concerns the system of any previous aspect in whichthe shark fin finger includes a tip vacuum cup.

Aspect 59 generally concerns the system of any previous aspect in whichthe shark fin finger includes a grip pad with one or more vacuum ports.

Aspect 60 generally concerns the system of any previous aspect in whichthe EoAT includes an extendable palm vacuum cup that is configured toextend from the EoAT.

Aspect 61 generally concerns the system of any previous aspect in whichthe tote with an internal separator supported on the shuttle.

Aspect 62 generally concerns the system of any previous aspect in whichthe internal separator includes a monolayer web configured to separatethe items.

Aspect 63 generally concerns the system of any previous aspect in whichthe monolayer web includes a grid of elastic bands.

Aspect 64 generally concerns the system of any previous aspect in whichthe grid has a perpendicular array of the elastic bands to separate theitems.

Aspect 65 generally concerns the system of any previous aspect in whichthe shuttle is configured to map position of the items in the tote forblind picking.

Aspect 66 generally concerns the system of any previous aspect in whichthe tote is configured to store multiple different kinds of StockKeeping Units (SKUs).

Aspect 67 generally concerns the system of any previous aspect in whichthe internal separator is configured to hold a uniform array of theitems with the same Stock Keeping Unit (SKU).

Aspect 68 generally concerns the system of any previous aspect in whichthe shuttle includes a vision system for picking dense random storage ofthe items in the tote.

Aspect 69 generally concerns the system of any previous aspect in whichthe rack system includes an elevator with an elevator platformconfigured to vertically move the shuttle.

Aspect 70 generally concerns the system of any previous aspect in whichthe elevator platform includes one or more rails that support theshuttle.

Aspect 71 generally concerns the system of any previous aspect in whichthe rails have a ramped section that is tapered for loading the shuttleonto the elevator platform.

Aspect 72 generally concerns the system of any previous aspect in whichthe elevator platform includes one or more retention brackets configuredto retain the shuttle during movement.

Aspect 73 generally concerns the system of any previous aspect in whichthe elevator includes a mezzanine entrance to transfer the shuttle to amezzanine

Aspect 74 generally concerns a method of operating the system of anyprevious aspect.

Further forms, objects, features, aspects, benefits, advantages, andembodiments of the present invention will become apparent from adetailed description and drawings provided herewith.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagrammatic view of a robotic shuttle system.

FIG. 2 is a perspective view of the FIG. 1 robotic shuttle system.

FIG. 3 is a top perspective view of the FIG. 1 robotic shuttle system.

FIG. 4 is an enlarged perspective view of the FIG. 1 robotic shuttlesystem.

FIG. 5 is an enlarged perspective view of a rack and shuttle in the FIG.1 robotic shuttle system.

FIG. 6 is a diagrammatic view of a shuttle used in the FIG. 1 roboticshuttle system.

FIG. 7 is a front perspective view of a shuttle used in the FIG. 1robotic shuttle system.

FIG. 8 is a rear perspective view of the FIG. 7 shuttle.

FIG. 9 is a front perspective view of a shuttle used in the FIG. 1robotic shuttle system.

FIG. 10 is a perspective view of an End of Arm Tool (EoAT) of the FIG. 9shuttle.

FIG. 11 is a top perspective view of a shuttle chassis.

FIG. 12 is a bottom perspective view of the FIG. 11 shuttle chassis.

FIG. 13 is a top perspective view of a lift mechanism for a shuttle.

FIG. 14 is a top perspective view of the FIG. 13 lift mechanism in araised position.

FIG. 15 is a top perspective view of the FIG. 13 lift mechanism in alowered position.

FIG. 16 is an enlarged perspective view of a drive assembly attached tothe FIG. 11 shuttle chassis.

FIG. 17 is an enlarged perspective view of the FIG. 16 drive assembly.

FIG. 18 is an exploded view of the FIG. 16 drive assembly.

FIG. 19 is a diagrammatic view of a shuttle charging system.

FIG. 20 is a top perspective view of a tote with a web managementsystem.

FIG. 21 is a top perspective view of the FIG. 20 tote with items held bythe web management system.

FIG. 22 is an enlarged perspective view of the rack in the FIG. 1system.

FIG. 23 is an enlarged perspective view of a shuttle entering a racklevel.

FIG. 24 is an enlarged perspective view of the shuttle entering a rackrow.

FIG. 25 is an enlarged perspective view of the shuttle moving along therack row.

FIG. 26 is an enlarged perspective view of the shuttle travellingtowards a service location.

FIG. 27 is an enlarged perspective view of the shuttle with the liftmechanism in the lowered position.

FIG. 28 is an enlarged perspective view of the shuttle with the liftmechanism in the raised position.

FIG. 29 is an enlarged perspective view of the shuttle removing a totefrom the rack.

FIG. 30 is an enlarged perspective view of the shuttle lowering thetote.

FIG. 31 is an enlarged perspective view of a robotic arm of the shuttleremoving an item from the tote.

FIG. 32 is an enlarged perspective view of the robotic arm of theshuttle placing the item on a shuttle tote.

FIG. 33 is an enlarged perspective view of the shuttle reloading thetote into the rack.

FIG. 34 is an enlarged perspective view of the shuttle travelling fromthe service location.

FIG. 35 is an enlarged perspective view of the shuttle travelling fromthe rack.

FIG. 36 is a perspective view of a storage rack system according toanother example.

FIG. 37 is an enlarged perspective view of one end of the FIG. 36storage rack system.

FIG. 38 is an enlarged perspective view of an elevator found in the FIG.36 storage rack system.

FIG. 39 is a front perspective view of a storage rack system accordingto a further example.

FIG. 40 is a rear perspective view of the FIG. 39 storage rack system.

FIG. 41 is a side view of the FIG. 39 storage rack system.

FIG. 42 is a front view of the FIG. 39 storage rack system.

FIG. 43 is an enlarged perspective view of one end of the FIG. 39storage rack system.

DETAILED DESCRIPTION OF SELECTED EMBODIMENTS

For the purpose of promoting an understanding of the principles of theinvention, reference will now be made to the embodiments illustrated inthe drawings and specific language will be used to describe the same. Itwill nevertheless be understood that no limitation of the scope of theinvention is thereby intended. Any alterations and further modificationsin the described embodiments, and any further applications of theprinciples of the invention as described herein, are contemplated aswould normally occur to one skilled in the art to which the inventionrelates. One embodiment of the invention is shown in great detail,although it will be apparent to those skilled in the relevant art thatsome features that are not relevant to the present invention may not beshown for the sake of clarity.

The reference numerals in the following description have been organizedto aid the reader in quickly identifying the drawings where variouscomponents are first shown. In particular, the drawing in which anelement first appears is typically indicated by the left-most digit(s)in the corresponding reference number. For example, an elementidentified by a “100” series reference numeral will likely first appearin FIG. 1, an element identified by a “200” series reference numeralwill likely first appear in FIG. 2, and so on.

A robotic shuttle system 100 will now be described with reference toFIG. 1. As shown, the robotic shuttle system 100 includes a rack system110, one or more shuttles 120, and a control system 130 that areoperatively connected to one another through a network 140. The controlsystem 130 assists in controlling the operation of the rack system 110and the shuttles 120. In addition, the control system 130 collects dataprovided by the shuttles 120 and the rack system 110. The shuttles 120are configured to operate autonomously and/or semi-autonomously relativeto one another so as to store and retrieve items stored in the racksystem 110.

Turning to FIG. 2, the rack system 110 includes one or more racks 205 onwhich items are stored, and a shuttle frame 210 on which the shuttles120 are able to travel along the racks 205. As shown, the racks 205include a series of storage rows 215 in which items are stored. Thestorage rows 215 of the rack 205 extend horizontally to form a series ofrack columns 220 with rack ends 222. In the illustrated example, theracks 205 extend vertically to form one or more rack levels 225. Inother examples, the racks 205 can be configured differently such ashaving fewer or more rows 215, columns 220, and/or rack levels 225.

The shuttle frame 210 allows the shuttles 120 to travel along the rack205 and service the various storage rows 215, rack columns 220, and racklevels 225. The shuttle frame 210 includes one or more rack accesspassages 230 through which the shuttles 120 are able to enter or exitthe rack system 110. The shuttles 120 are able to independently movealong the floor outside of the rack system 110 so as to transfer itemsbetween various external service locations and the rack system 110.

Looking at FIGS. 3 and 4, the shuttle frame 210 includes a one or moreelevator sections 305 that allow the shuttle 120 to move vertically soas to access the various rack levels 225 in the rack system 110. Asshown, the shuttle frame 210 further includes one or more travel lanes310 that allow the shuttle 120 to travel along the rack columns 220 andaround the ends of the racks 205 so that the shuttle 120 is able toaccess the various storage rows 215 along the racks 205 at particularrack levels 225. Where the elevator sections 305 and/or travel lanes 310meet one another, the shuttle frame 210 has intersections 315 that aredesigned to allow the shuttles 120 to change their direction,horizontally and/or vertically. In the illustrated example, the shuttleframe 210 has travel lanes 310 sandwiched between rack columns 220. Thetravel lanes 310 also extend across the ends of the racks 205 to allowthe shuttles 120 to access other travel lanes 310 that are locatedbetween other rack columns 220. In other examples, the travel lanes 310can be located elsewhere such as long the outside or periphery of theracks 205 such that the travel lane 310 is not located between rackcolumns 220. Along the travel lanes 310, the shuttle frame 210 has rackrails 320 located on opposite sides of the shuttle 120. In some exampleswhich will be described below, the rack rails 320 have teeth that engagewith the pinion gear or pinion wheel on the shuttle 120 so as to enhancetraction. In other examples, the rails 320 are smooth and lack teeth. Atthe intersection 315, the shuttle frame 210 has turn rails 325 that areconfigured to allow the shuttle 120 to change its horizontal traveldirection. As will be explained below, the turn rails 325 are configuredto engage the outer, larger wheel section of the shuttle 120 that isable to ride on the ground. The turn rails 325 are arranged in astraight, rectangular fashion and include turning shoulders thatfacilitate or allow rotation of the wheels of the shuttle 120. In otherexamples, the turn rails 325 can be oriented and/or shaped differentlythan is illustrated. For instance, the turn rails 325 in othervariations can have curved shapes. The shuttle frame 210 at the rackaccess passages 230 has access rails 330 that are angled so as to allowthe shuttles 120 to ride up into the shuttle frame 210 or down out ofthe shuttle frame 210. In the illustrated examples, each rack accesspassage 230 has two opposing access rails 330 that are engaged by wheelson opposing sides of the shuttle 120.

Upon entering the rack access passage 230, the shuttle 120 is able totravel vertically (i.e., up or down) via the elevator sections 305 ofthe shuttle frame 210. The shuttles 120 are then able to transition fromthe elevator sections 305 onto one of the intersections 315. From theintersection 315, the shuttle 120 is able to turn via the turn rails 325down a particular travel lane 310 located between rack columns 220, orthe shuttle 120 can travel along one of the travel lanes 310 located atthe end of the racks 205 so as to access a different travel lane 310that travels along the rack columns 220. FIG. 5 shows of an enlargedview of one example of the shuttle 120 traveling vertically along theelevator section 305 of the shuttle frame 210. As illustrated, theelevator section 305 includes elevator rails 505 that extend verticallyto facilitate travel of the shuttle 120 in vertical directions. Theelevator rails 505 include rack sections 510 having teeth that areconfigured to engage the pinion wheels of the shuttle 120 so as tofacilitate vertical movement. The shuttle frame 210 in the elevatorsection 305 can have transition rails 515 with rack sections 510configured to engage the pinion wheels of the shuttle. As shown, thetransition rails 515 extend transverse to the elevator rails 505 suchthat the transition rails 515 extend in a general horizontal direction.Between the elevator rails 505 and the transition rails 515, theelevator section 305 has one or more shuttle switches 520 that are ableto change the movement of the shuttle 120 between a vertical directionand a horizontal direction. The shuttle switch 520 is designed tofacilitate not only vertical and horizontal movement of the shuttle 120,but the switch shuttle switch 520 also allows the shuttle 120 totransition from a vertical trajectory to a horizontal directory and viceversa. In one example, the switch 520 is actuated by the control system130. In another example, the individual shuttles 120 are able to actuatethe switch 520.

As shown, the shuttle switch 520 includes a turntable 525 with one ormore curved track sections 530. In the illustrated example, the curvedtrack sections 530 are curved in an opposing manner. That is, one of thecurved track sections is concavely curved while the other is convexlycurved. As shown, each curved track section 530 includes a side withteeth and an opposing side without teeth. Between the curved tracksections 530, the turntable 525 of the shuttle switch 520 has a straighttrack section 535. Like the curved track sections 530, the straighttrack section 535 has one side with teeth and an opposing side withoutteeth that form a channel in which the wheels of the shuttle 120 areguided. The teeth in the track sections 530, 535 allow the wheels of theshuttle to engage and move vertically and/or horizontally depending onthe specific requirements.

To allow vertical movement along the elevator rails 505, the shuttleswitch 520 is rotated to align the straight track section 535 with theelevator rails 505. Once the shuttle 120 clears the shuttle switch 520,the shuttle switch 520 can be rotated so as to facilitate transitioningof the shuttle 120 from the elevator rails 505 to the transition rails515 so as to facilitate horizontal movement of the shuttle 120. Thecurved track sections 530 are aligned with the transition rails 515 toform a pathway between the elevator rails 505 and the transition rails515. The shuttle 120 then able to move from the elevator rails 505 tothe transition rails 515 so as to facilitate horizontal movement. In asomewhat similar fashion, the shuttle switch 520 can be oriented so asto facilitate transitioning of the shuttle 120 from horizontal movementto a vertical movement along the elevator sections 305. The shuttleswitch 520 is rotated such that the curved track section 530 is alignedwith both the transition rails 515 as well as the elevator rails 505. Atravel pathway then is formed between the transition rails 515 and theelevator rails of 505 on which the shuttle 120 is able to move from ahorizontal direction to a vertical direction. In one example, theelevator sections 305 and/or travel lanes 310 are designated for travelin a single direction. For instance, one or more of the elevatorsections 305 are designated to only allow travel in a single direction(e.g., up) and another set of elevator sections 305 can be designatedfor travel in the opposite direction (e.g., down). In another variation,some or all of the elevator sections 305 and/or travel lanes 310 allowtravel in both directions. It should be recognized that in furthervariations the combination of these approaches can be used in which someonly allow travel in a single direction while others allow travel in twoor more directions.

As noted before, the intersections 315 have turn rails 325 that allowthe shuttles 120 to change their horizontal travel direction. The turnrails 325 have rail channels 540 designed to receive the wheels of theshuttle 120. The rail channels 540 prevent the wheels from slipping offof the turn rails 325 and provide guidance. At the corners of the turnrails 325, the turn rails 325 have turn shoulders 545 that provide spacefor allowing turning of the wheels of the shuttle 120. In theillustrated example, the turn shoulders 545 have an arc shape thatextends outwardly from the turn rails 325 such that when in the turnshoulders 545, the wheels of the shuttle 120 are able to turn.

FIG. 6 shows a diagrammatic view of the shuttle 120. While FIG. 6illustrates the components as being distinct from one another, it shouldbe recognized that one or more of these components can be combinedtogether to form an integral unit and/or selected components may befurther subdivided and their function spread across multiple devices. Asshown, the shuttle includes a robotic arm 605, a container transfermechanism 610, a powertrain 615, a guidance system 620, and an energysource 622. The robot arm 605 is configured to pick or place items fromvarious containers such as trays or totes located on the shuttle 120.The container transfer mechanism 610 is configured to load and unloadcontainers, such as trays, from the racks 205 and onto the shuttle 120.The powertrain 615 is configured to move the shuttle 120 inside andoutside of the rack system 110. A guidance, navigation, and control(GNC) system 620 controls the movement and directs the travel path ofthe shuttle 120. The energy source 622, such as a battery or supercapacitor, provides energy to the various components of the shuttle 120,as is indicated by the dashed line in FIG. 6. The shuttle 120 furtherincludes a processor 625, memory 630, a communication system 635, andone or more sensors 640. As shown, the processor 625 communicates withand controls the various components of the shuttle 120, and the memory630 is used to store information from the processor 625 that concernsthe shuttle 120, rack system 110, and/or other information. Thecommunication system 635 is configured to communicate with the controlsystem 130 and/or other shuttles 120 through the network 140. Thecommunication system 635 in one example includes a radio transceiver,but in other variations, the communication system 635 can communicate inother ways. The sensors 640 are configured to sense the environmentsurrounding the shuttle as well as internal functions or parameterswithin the shuttle 120. For example, the sensors 640 can include visionsystems, light curtains, proximity sensors, thermocouples, and/or othertypes of sensors. In the illustrated example, the robot arm 605, thecontainer transfer mechanism 610, the powertrain 615, the GNC system620, the energy source 622, memory 630, the communication system 635,and sensors 640 are operatively connected to the processor 625. Itshould be recognized that these components of the shuttle 120 can beconnected in other manners. For instance certain components can bealternatively or additionally operatively connected to one another suchthat the components can directly communicate with one another withoutthe processor 625. Moreover, the various components of the shuttle 120can be powered in other manners than is it is illustrated.

FIGS. 7 and 8 respectively show front and rear perspective views of oneexample of the shuttle 120. As can be seen, in addition to the robot arm605, the container transfer mechanism 610, the powertrain 615, the GNCsystem 620, and the sensors 640, the shuttle 120 includes the othercomponents depicted in FIG. 6. The shuttle 120 includes a chassis 705,and a body 710 mounted to the chassis 705. Portions of the powertrain615 and/or the GNC system 620 are incorporated into one or more wheelassemblies 715. The wheel assemblies 715 are turnably mounted to thechassis 705 such that the wheel assemblies 715 are able to move andsteer the shuttle 120. The wheel assemblies 715 in the shuttle 120 aredesigned to turn independently of one another when required to allow theshuttle 120 to turn or change the horizontal direction of the shuttle120 when in the shuttle frame 210. Since the space is typically tightwithin the rack system 110, the shuttle 120 is unable to usually makewide turns. To facilitate a zero turning radius turn within the shuttleframe 210, the wheel assemblies 715 on opposing sides are able to turnin opposite directions at least ninety degrees (90°) relative to thebody 710 of the shuttle 120. The body 710 of the shuttle 120 has wheelwells 718 that form notches the corners of the shuttle 120 to allow thisturning and allow the wheel assemblies 715 to move the shuttle 120 in ahorizontal direction that is transverse or perpendicular to the originaltravel direction. When outside (or even inside) the rack system 110, thewheel assemblies 715 can turn in unison to steer the shuttle 120 whentravelling on the floor or ground, for example. The robot arm 605 andthe container transfer mechanism 610 are likewise mounted to the chassis705 along with the other internal components of the shuttle 120.

As can be seen, the body 710 includes a container holder 720 on whichone or more containers can be supported. The container holder 720 hasone or more holder walls 725 that forms a container cavity 730 in whichthe container is received. The holder walls 725 of the container holder720 reduce the risk of a container sliding off the shuttle 120 duringmovement as well help to fix the location of the container duringrobotic picking and/or placing items into the container. The containertransfer mechanism 610 is located between the robot arm 605 and thecontainer holder 720. The container transfer mechanism 610 has a rackcontainer platform 735 on which trays, totes and/or other containers orobjects are loaded from the racks 205. The container transfer mechanism610 further includes one or more extendable conveyors 740 that are ableto extend laterally from the shuttle 120 at a position underneath thetarget tray from the storage row 215 in the rack 205. In one example,the container transfer mechanism 610 includes a pair of extendableconveyors 740, each of which being extendable belt conveyors. In anotherexample, the extendable conveyor can include other types of conveyors orsimply be forks for drawing the tray onto the shuttle 120. Theextendable conveyor 740 is able to extend from both sides of the shuttle120 so as to service racks 205 located on opposite sides of the shuttle120. As will be explained below, the container transfer mechanism 610 isable to extend vertically, both above and below the shuttle 120 suchthat the shuttle 120 is able to service rack levels 225 that are aboveor below the rack level 225 where the shuttle 120 is located. The robotarm 605 includes an End of Arm Tool (EoAT) 745 that is able to grab orotherwise manipulate objects such as items. In one example, the robotarm 605 includes a six-axis robot arm, but other types of robot arms canbe used in other examples. The robot arm 605 along with the EoAT 745transfer items between the containers on the rack container platform 735and the container holder 720.

FIG. 9 illustrates another example of a shuttle 900 that operates in therack system 110 of the robotic shuttle system 100. The shuttle 900contains the same components as discussed before with respect to FIGS.6, 7, and 8, and only the differences between the two will be describedbelow. For example, the shuttle 900 includes the chassis 705, body 710,wheel assembly 715, container holder 720, container cavity 730, rackcontainer platform 735, and extendable conveyor 740 as described abovewith respect to the shuttle 120 depicted in FIGS. 7 and 8. Likewise, theshuttle 900 includes the components and subcomponents of the shuttle 120depicted in FIG. 6. As can be seen, the shuttle 900 includes a robot arm905 with a unique EoAT 910. As shown in FIG. 9, the shuttle 900 has oneor more containers 915 loaded on the container holder 720 and the rackcontainer platform 735. It should be recognized that the containers 915can be the same in terms of size, shape, configuration, etc., ordifferent. In the illustrated example, the container 915 that isresiding on the shuttle 900 (or 120) in the container holder 720 is atray 920, and the container 915 on the rack container platform is a tote925. The location of the trays 920 and totes 925 on the shuttle 900 (or120) can be reversed. For example, the trays 920 can be stored on theracks 205 and totes 925 can be positioned in the container holder 720.Moreover, other types of containers 915 besides those illustrated in thedrawings can be used in the robotic shuttle system 100. It should bealso recognized that the same type of containers 915 can be used at bothlocations on the shuttle 900.

FIG. 10 shows a perspective view of the EoAT 910 shown in FIG. 9 in anopen position. This unique EoAT 910 is further described in U.S.Provisional Patent Application No. 62/593,779, filed Dec. 1, 2017,entitled “End Effector” which is hereby incorporated by reference in itsentirety. The EoAT 910 is designed for manipulating items and includes aunique combination of shark fin grippers with strategically placedvacuum cups. As particularly shown, the EoAT 910 includes one or moreshark fin fingers or gripping members 1005 that are pivotally connectedto a hub 1010. In the illustrated in example, the EoAT 910 includesthree shark fin fingers 1005, but other examples can include more orless shark fin fingers than is shown. The EoAT 910 further includes anextendable palm vacuum cup 1015 that is able to extend in a telescopingmanner from the hub 1010 to pick up relatively small or fragile itemsnot suitable for picking by the shark fin fingers 1005. The shark finfingers 1005 are generally flexible in nature and include grip pads 1020that are made of an elastomeric material. The grip pads 1020 define oneor more vacuum ports 1025 that are able to create a vacuum (i.e., anarea of low pressure) to grip items. At the tip, each shark finger 1005has a tip vacuum cup 1030 that is designed to pick up relatively smallitems with vacuum or suction. This unique combination allows the EoAT910 to pick a wide variety of items both large and small as well asthose that are difficult to handle. For example, the EoAT 910 allowsindividual products to be picked up via the shark fin fingers 1005 thatclose together to grip the item. In another example, a vacuum pickup canoccur via the extendable palm vacuum cups 1015 and or the vacuum ports1025 which is then followed by using the shark fingers 1005 grippingtogether to further secure the item. A single gripping option can beused where the tip vacuum cups 1030 are used alone, and in anothervariation, a multi-tipped configuration can be used in which the tipvacuum cups 1030 are brought closer together and all of the tip vacuumcups 1030 are used to pick up the individual items. A single tip vacuumcup 1030 can be used to pick up individual items as well. Of course,there other ways in which the EoAT 910 can pick and/or manipulate items.

For the purpose of explanation, the components, both internal andexternal to both shuttles 120 and 900, will be described together in thefollowing drawings with respect to the shuttle 120 shown in FIGS. 7 and8, for the sake of clarity. Both shuttles 120, 900 as noted before sharecommon components and function generally in the same manner within therobotic shuttle system 100. The discussion below of the varioussubcomponents and operational methods with reference to the FIG. 7shuttle 120 equally applies to the FIG. 9 shuttle 900. FIGS. 11 and 12respectively show top perspective and bottom perspective views of theshuttle 120 (900) with the body 710 and other selected componentsremoved from the shuttle 120. As depicted, the power source 622, sensors640, and wheel assembly 715 are mounted to the chassis 705. A shuttlecontroller 1105 in the form of a computer that includes the processor625 and memory 630 is also mounted to the chassis 705. The controller1105 controls the operation of the components of the shuttle 120. Thechassis 705 defines a lift cavity 1110 in which a lift mechanism of thecontainer transfer mechanism 610 is received.

A lift mechanism 1300 for the container transfer mechanism 610 that issecured inside the lift cavity 1110 of the chassis 705 will now bedescribed with reference to FIGS. 13, 14, and 15. The unique design ofthe illustrated lift mechanism 1300 allows the rack container platform735 to extend above and below the shuttle 120. The unique design of thelift mechanism 1300 is further described in US Provisional PatentApplication No. 62/593,800, filed Dec. 1, 2017, entitled “Scissor Lift”which is hereby incorporated by reference in its entirety. As shown, thelift mechanism 1300 includes a base 1305, a platform support frame 1310,and a scissor linkage assembly 1315 operatively connecting the base 1305to the platform support frame 1310. The lift mechanism 1300 furtherincludes one or more actuator motors 1320 that are configured toarticulate the scissor linkage assembly 1315 so as to raise or lower theplatform support frame 1310 relative to the base 1305. The base 1305 isconnected or secured to the chassis 705 at the lift cavity 1110. Thebase 1305 defines a platform cavity 1325 in which the platform supportframe 1310 is received when the lift mechanism 1300 is in a neutralconfiguration, such as is shown in FIG. 13. Turning to FIG. 14, theactuator motors 1320 can be used to move or actuate the scissor linkageassembly 1315 so as to raise the platform support frame 1310 relative tothe base 1305. The shuttle controller 1105 can lower the rack containerplatform 735 by actuating the actuator motors 1320 so as to cause thescissor linkage assembly 1315 to lower the platform support frame 1310below the base 1305, as is depicted in FIG. 15. In other examples, othertypes of actuators and linkage assemblies can be used to raise and lowerthe rack container platform 735.

As noted before, the wheel assembly 715 incorporates portions of thepowertrain 615 and GNC system 620. Portions of the powertrain 615 andGNC system 620 are incorporated into other components of the shuttle 120such as in the shuttle controller 1105 and sensors 640. As shown in FIG.16, the wheel assembly 715 includes a drive wheel 1605 that isconfigured to ride on the floor, ground, turn rails, and or otherobjects that that allow the shuttle 120 to be self-supported. The drivewheels 1605 can be a solid component, include spokes, and/or incorporateother components such as tires. Facing exterior to the drive wheels1605, the wheel assembly 715 has one or more pinions 1610. The pinions1610 are designed to engage the teeth sections of the track sections530, 535 of the elevator section 305, rack rails 320, transition rails515, shuttle switches 520, and/or other structure having teeth. Thepinions 1610 have pinion teeth 1615 that engage the rack sections so asto provide traction as well as accurately control the position of theshuttle 120 when in the rack system 110. In one example, the drive wheel1605 and pinion 1610 are able to be moved or rotated independentlyrelative to one another. In another example, the drive wheel 1605 andpinion 1610 rotate in unison.

Looking at FIGS. 17 and 18, the wheel assembly 715 has a mountingbracket 1705 where the wheel assembly 715 is attached to the chassis705. The wheel assembly 715 includes a steering system 1708 that is usedto steer the drive wheel 1605 and pinion 1610. In the illustratedexample, the steering system 1708 includes a steering collar 1710 with afixed section 1715 secured to the mounting bracket 1705 and a rotatingsection 1720 that is able to rotate relative to the fixed section 1715.The steering system 1708 further includes a steering motor 1725 that isconfigured to rotate the rotating section 1720 relative to the fixedsection 1715. In one form, bearings and lubricant are positioned betweenthe sections 1715, 1720 so as to reduce friction, but in other systemsother mechanisms can be used to reduce friction. The steering motor 1725in one variation is configured to rotate the rotating section 1720 ofthe steering collar 1710 through a rack and pinion type connection, butother types of connections can be used such as through a helical screwtype thread type engagement between the steering motor 1725 and therotating section 1720 of the steering collar 1710. The GNC system 620 ofthe shuttle controller 1105 controls the travel direction or steering ofthe shuttle 120 through the steering motor 1725. In one example, thesteering motor 1725 includes a reversible electric motor, but othertypes of motors can be used in other examples. A wheel bracket 1730 issecured to the rotating section 1720 via fasteners. A drive motor 1735with a gearbox 1737 which together forms part of the powertrain 615 issecured to the wheel bracket 1730. A drive shaft 1740 connects the drivewheel 1605 and pinion 1610 to the drive motor 1735. In one form, thedrive motor 1735 includes a reversible electric motor so as to be ableto rotate the drive wheel 1605 and pinion 1610 in opposite or differentdirections so as to change the velocity and/or direction of the shuttle120. To control, slow down, and/or stop the shuttle 120, the wheelassembly 715 further includes a brake system 1745. As depicted, thebrake system 1745 includes a brake disc 1750 that is engageable by abrake caliper system 1755. The brake system 1745 is able to hold theshuttle 120 at a fixed or steady location, such as when servicing one ofthe racks 205. Moreover, the brake system 1745 is able to quickly stopthe shuttle 120 if needed. The illustrated example shows a disc braketype system, but in other variations, the shuttle 120 can include othertypes of brake systems 1745, such as drum type brakes or electromagneticbraking systems. As noted before, the wheel assembly 715 in one form isconfigured to allow the pinion 1610 to be rotated independently of thedrive wheel 1605. In the illustrated example, the wheel assembly 715includes a pinion bearing 1760 to facilitate this relative movement. Inanother variation, the drive wheel 1605 and pinion 1610 rotate inunison. In other approaches one or more of the drive wheels 1605 and/orpinions 1610 on the shuttle are unpowered and rotate freely. Of course,a combination of approaches can be used in further examples.

A charging system 1900 for charging the energy source 622, such as abattery and/or capacitor, will now be described with reference to FIG.19. The charging system 1900 corresponds to the charging systemsdescribed in US Provisional Patent Application No. 62/503,211, filed May8, 2017, entitled “Charging System for Autonomous Mobile Unit” which ishereby incorporated by reference in its entirety. As shown, the chargein system 1900 includes a charge storage device 1905, such as a battery,and a charge control device 1910 that controls the amount of electricalpower supplied to the charge storage device 1905 for rechargingpurposes. In the illustrated example, the rack rails 320 areelectrically powered to form a circuit in order to charge the chargestorage device 1905. In one form, direct current (DC) is applied betweenthe rack rails 320, and in another example, alternating current (AC) isprovided between the rack rails 320. An electrical flow path isindicated by dashed line 1915 in FIG. 19. In the illustrated example,the flow path 1915 travels from the rack rail 320 into the pinion 1610,through the drive wheel 1605 through the drive shaft 1740 and drivemotor 1735. The electrical flow path 1915 flows through the chargecontrol device and continues to flow in the opposite manner through theopposing drive motor 1735, drive shaft 1740, drive wheel 1605, pinion1610 and to the opposing rack rail 320. The charge control device 1910is electrically connected to the charge storage device 1905 through anelectrical connection 1920. The electrical power provided by the flowpath 1915 is converted by the charge control device 1910 and suppliedvia the electrical connection 1920 to the charge storage device 1905. Itshould be recognized that the flow path 1915 can float through differentcomponents in other examples.

Since the shuttle 120, 900 moves, items within the container 915 canshift, move, tip over, and/or fall out of the container 915. Items canalso shift when the trays 920 are removed from the racks 205 or duringreshelving. This shifting of items in the container 915 can make itdifficult for the robot arm 605 from picking or putting items into thecontainer 915. Moreover, the robot arm 605 further requires a visionsystem or other item location sensors in order to make adjustments so asto locate and manipulate the items within the container 915. Visionsystems can be quite expensive and difficult to maintain. Turning toFIGS. 20 and 21 a container 2000 with a separator system 2005 forinternally organizing items within the container 2000 has beendeveloped. As shown, the separator system 2005 includes a separator web2010 that stretches across an opening 2015 of the container 2000. Theseparator system 2005 defines web openings 2020 for receiving items. Theseparator web 2010 is formed by a network of elastic bands or cords 2025that are interwoven or interlaced with one another. The elastic bands2025 are made of an elastic material that allows the elastic bands 2025to stretch and accommodate items of varying sizes as well as retain theitems within the container 2000. The ends of the elastic bands 2025 aresecured to the container 2000 by being secured to one or more web slots2030 defined in the container 2000. In the illustrated example, theelastic bands 2025 are arranged or woven together in a generally uniformpattern in FIG. 20. The separator web 2010 is in the form of a monolayerwithin the container 2000 so as to form a single layer. It should berecognized that the container 2000 can include multiple layers ofseparator webs 2010 in other examples. The container 2000 furtherincludes a skid pad 2035 at the bottom of the container 2000 to minimizeslippage of items within the container 2000. The elastic bands 2025 canbe rearranged depending on the requirements of a particular situation.For example, as is shown in FIG. 21, the elastic bands 2025 can bearranged in an irregular pattern so as to accommodate items 2105 ofvarying sizes and/or shapes. While the illustrated examples show theelastic bands 2025 arranged in a grid pattern, the elastic bands 2025 inother examples can be arranged in other patterns, such as pinwheel orspider web patterns. Once more, the separator web 2010 helps to minimizemovement of the items 2105 within the container 2000 during movement. Byhaving the items 2105 in a stabilized position, the robot arm 605 isable to perform blind picking in which a vision system is not necessaryto locate the items 2105 during picking or placing, but a vision systemcan be used if so desired.

A technique for operating the robotic shuttle system 100 will now bedescribed with reference to FIGS. 22-35. The shuttle 120 (or 900) isable to autonomously operate outside of the rack system 110. The shuttle120 enters the shuttle frame 210 of the rack system 110 through one ofthe rack access passages 230 as indicated by arrow 2205 in FIG. 22.

Referring to FIGS. 5 and 23, the shuttle 120 uses the pinion 1610 totravel vertically up the elevator section 305 via the elevator rails505. The pinions 1610 have the pinion teeth 1615 engaged tocorresponding teeth on the elevator rails 505. Once the shuttle 120reaches a target shuttle frame level 2305, the shuttle switches 520 arerotated as indicated by arrow 2310 in FIG. 23 such that the curved tracksection 530 of each shuttle switch 520 aligns with the elevator rails505 and the transition rails 515 at the shuttle frame level 2305. Thepinions 1610 of the shuttle 120 then travel from the elevator rails 505,along the curved track sections 530 of the shuttle switches 520, andonto the transition rails 515. As indicated by arrow 2315 in FIG. 23,the pinions 1610 of the shuttle 120 then travel along the transitionrails 515 towards the intersection 315. As the shuttle 120 continues totravel in direction 2315, the shuttle switches 520 are again rotated asindicated by arrow 2310 such that the straight track sections 535 of theshuttle switches 520 are aligned with the transition rails 515 so thatthe shuttle 120 is able to transfer from the transition rails 515 ontothe turn rails 325. The transition rails 515 are spaced above the turnrails 325 generally based on the radial difference between the pinion1610 and a drive wheel 1605. When transitioning onto the turn rails 325,the drive wheels 1605 engage and ride along the turn rails 325 and thepinions 1610 disengage or ride off the transition rails 515.

At the intersection 315, the shuttle 120 is able to travel along theends of the racks 205. Once the shuttle 120 is fully loaded on the turnrails 325 at a particular intersection 315, the shuttle 120 is then able(if needed) to turn so as to travel down the appropriate travel lane 310towards the target storage row 215 in the rack 205. Once more, the turnrails 325 have rail channels 540 that inhibit the drive wheels 1605 ofthe shuttle 120 from falling off the shuttle frame 210. As shown byarrows 2405, 2410 the drive wheels 1605 of the wheel assembly 715 of theshuttle 120 are able to rotate in opposing directions at ninety degrees(90°) relative to the shuttle 120. As noted before, the corners of theturn rails 325 at the intersection 315 have turned shoulders 545 thatallow the drive wheels 1605 to turn ninety degrees (90°) relative to therest of the shuttle 120. The steering system 1708 is designed to allowthe wheel assembly 715 to turn independently with one another whenrequired, such as turning in the depicted fashion, as well as steer inunison such as when the shuttle 120 operates outside of the rack system110. To facilitate high packing densities within the rack system 110,the amount of free space within the rack system 110 is rather small. Theability of the shuttle 120 to make sharp turns with a zero turningradius within the shuttle frame 210 allows for higher packing densities.This zero turning radius ability allows the shuttle 120 to turn in atransverse direction relative to the original travel direction and isfacilitated by the wheel assembly 715 being able to turn in an opposingmanner at least ninety degrees (90°) relative to the rest of the shuttle120. As noted before, the body 710 has wheel wells 718 that form notchesat the corners of the shuttle 120 to allow this zero turning radiusturn. Once the shuttle 120 is turned, the shuttle 120 is able to traveldown the appropriate travel lane 310 as is indicated by arrow 2505 inFIG. 25.

In the subsequent drawings, portions of the rack system 110 have beenremoved to enhance visibility. For example, one of the rack columns 220along with the corresponding rack rail 320 have not been shown in FIG.26 and the subsequent drawings so that the shuttle 120 is visible as theshuttle 120 travels down a travel lane 310. Turning to FIG. 26, theshuttle 120 when traveling down a travel lane 310 has the pinions 1610engaged with and riding on the rack rails 320. The intermeshing of thepinions 1610 with the teeth of the rack rails 320 facilitates accuratelocation determination of the shuttle 120, either by dead-reckoningalone or in combination with other location determination techniques.Once more, the rack rails 320 have teeth that engage the pinion teeth1615 on the pinions 1610 of the wheel assembly 715. Again, the shuttle120 is supported on both sides by the rack rails 320. As indicated byarrow 2605, the shuttle 120 travels along the travel lane 310 until theshuttle 120 reaches a target storage row 2610 containing one or morecontainers 915 to be serviced by the shuttle 120. As mentioned before,the rack system 110 can store a variety of containers 915. In theillustrated example, the racks 205 store both trays 920 and totes 925.The racks 205 at the storage rows 215 have opposing L-brackets 2615 thatsupport the corners or sides of the containers 915. The L-brackets 2615form a gap that allows the extendable conveyor 740 of the shuttle toengage the bottom of the containers 915.

Upon reaching a target storage row 2610, the lift mechanism 1300 of theshuttle 120 can be raised or lowered so that the shuttle 120 is able toretrieve containers on rack levels 225 that are above or below thecurrent shuttle frame level 2305, as is shown in FIGS. 27 and 28.

Looking at FIG. 27, the lift mechanism 1300 lowers the rack containerplatform 735 to the rack level 225 containing the target container 915as is indicated by arrow 2705. The extendable conveyor 740 is extendedunderneath the container 915, and the lift mechanism 1300 slightlyraises the rack container platform 735 so that the extendable conveyors740 are able to support the bottom of the container 915 on the rack 205.In one variation, belts on the extendable conveyor 740 are powered todraw the container 915 onto the rack container platform 735. In anothervariation, the extendable conveyors 740 are in the form of forks thatlift and draw in the container 915 onto the rack container platform 735.Once the container 915 is fully loaded onto the rack container platform735, the lift mechanism 1300 raises the container 915 to a neutralposition where the rack container platform 735 is generally level withthe rest of the shuttle 120. As noted before, the lift mechanism 1300along with the shuttle 120 defines a platform cavity that allows thecontainer 915 on the rack container platform 735 to rise up and throughthe bed of the shuttle 120. The platform cavity 1325 is sized to belarger than the containers 915 that are being serviced so that thecontainers 915 are able to fit through the platform cavity 1325. Inother variations, the containers 915 that are larger than the platformcavity 1325 are always placed at a position that is above the shuttle120 and/or the shuttle is on a shuttle frame level 2305 that is belowthe large containers 915. In further forms, the lifting mechanism 1300may have the rack container platform 735 positioned slightly below orabove the shuttle during servicing (i.e., not at the neutral position)so that the robot arm 605 can more easily and/or efficiently move itemsbetween the containers 915 on the rack container platform 735 and thecontainer holder 720.

FIGS. 28, 29, and 30 illustrate a sequence of actions performed by theshuttle 120 when loading a container 915 that is located above theshuttle 120 at the shuttle frame level 2305. As illustrated in FIG. 28,the lifting mechanism 1300 raises the rack container platform 735 in anupward direction 2805. Once at the appropriate level, the extendableconveyors 740 are extended in a (horizontal) extension direction 2810 soas to be positioned underneath the container 915 on the rack 205. FIG.29 shows the container 915 being drawn onto the rack container platform735 by retracting the extendable conveyors 740 in a (horizontal)retraction direction 2905. Once the container 915 is fully loaded ontothe rack container platform 735, the lift mechanism 1300 lowers the rackcontainer platform 735 in a downwards direction 3005 towards the shuttle120, as is depicted in FIG. 30.

Referring to FIGS. 31 and 32, in the illustrated example one of thetrays 920 is loaded from the rack 205. The container 915 in thecontainer holder 720 of the shuttle 120 is a tote 925.

Once more, the tray 920 and tote 925 can be reversed, or the same typeof container 915 can be used at both positions. The tray 920 from therack 205 contains a single item 2105, but in other examples, the tray920 can contain multiple items 2105. The robot arm 605 grabs the item2105 with the EoAT 745. The robot arm 605 then moves the item 2105 fromthe tray 920 on the rack container platform 735 and into the tote 925 onthe container holder 720 of the shuttle 120, as is shown in FIG. 32.Once the item 2105 is placed in the tote 925, the EoAT 745 releases theitem 2105. The robot arm 605 can repeat the process of moving items 2105from the tray 920 into the tote 925. This process can be reversed so asto restock items 2105 in the rack 205 by transferring items 2105 fromthe tote 925 on the shuttle 120 into the tray 920. Another variation isa combination approach in which some of the items 2105 are restockedwhile other items 2105 are added to the tray 920. Once the tray 920(i.e., container 915) has been serviced by transferring items 2105 fromthe tray 920 to the tote 925, transferring items 2105 from the tote 925to the tray 920, or both, the tray 920 is returned to the rack 205. Insome examples, the tray 920 or other container 915 can remain on therack container platform 735 so as to increase the load capacity of theshuttle and/or for replacement/servicing of the tray 920 for example.

Turning to FIG. 33, the lift mechanism 1300 raises the platform in theupward direction 2805. The extendable conveyor 740 then moves the tray920 in the extension direction 2810 so as to reshelve the tray 920 backinto the rack 205. In other examples, the shuttle 120 can reshelve thecontainer 915 at a different location in the rack 205 that is differentfrom the original position. The shuttle 120 then can move along the racksystem 110, as indicated by arrow 3405 in FIG. 34, so as to serviceadditional containers 915 and/or travel outside of the rack system 110such as is depicted in FIG. 35. The shuttle 120 can exit one of the rackaccess passages 230 and travel, as indicated by arrow 3505, to aservicing location outside of the rack system 110 towards a servicestation. At the service station, the items 2105 can be transferred orremoved from the shuttle 120 or further processed. Other items 2105 canbe placed on the shuttle 120 so as to be restocked in the rack system110. As should be recognized, the robotic shuttle system 100 can be usedin a wide variety of situations, such as order fulfillment and/orproduct buffering. The robotic shuttle system 100 provides an efficientand cost-effective manner for storing, reorganizing, and retrievingmultiple kinds of SKUs.

FIGS. 36, 37, and 38 illustrate another example of a storage rack system3600 that can be used in the robotic shuttle system 100 of FIG. 1. Aswill be recognized, the storage rack system 3600 shares a number ofcomponents in common with and operates in a similar fashion to theexamples illustrated and described before. For the sake of brevity aswell as clarity, these common features will not be again described belowin detail, but please refer to the previous discussion. Only the notabledistinctions between the storage rack system 3600 and the examplesdescribed before will be discussed, and unless indicated otherwise, thestorage rack system 3600 in FIG. 36 shares the same components andoperates in the same fashion as the examples described before.

For example, the storage rack system 3600 includes one or more shuttles3605, racks 3610, and shuttle frames 3615. The shuttle 3605 isconfigured in the same fashion as the other shuttles 120 describedbefore. In one form, the shuttle 3605 is configured in the same orsimilar fashion as the shuttle 900 depicted in FIG. 9. Typically, butnot always, the shuttle 3605 includes the robot arm 905 with the EoAT910. In other variations, the shuttle 3605 does not include the robotarm 905 with the EoAT 910. In the illustrated example, the robot arm 905is not shown on the shuttle 3605 so as to enhance visibility of othercomponents. Once more, the shuttles 3605 are configured to operateautonomously and/or semi-autonomously relative to one another so as tostore and retrieve items stored in the storage rack system 3600. Theshuttle 3605 is able to move independently inside or outside of theracks 3610.

Like before, the storage rack system 3600 includes the rack 3610 onwhich items are stored, and the shuttle frames 3615 on which theshuttles 3605 are able to travel along the racks 3610. As shown, eachrack 3610 includes a series of storage rows 215 in which items arestored.

The storage rows 215 of the rack 3610 extend horizontally to form aseries of rack columns 220 with rack ends 222. In the illustratedexample, the racks 3610 extend vertically to form one or more racklevels 225. In other examples, the racks 205 can be configureddifferently such as having fewer or more storage rows 215, rack columns220, and/or rack levels 225.

The shuttle frame 3615 allows the shuttles 3605 to travel along theracks 3610 and service the various storage rows 215, rack columns 220,and rack levels 225. As shown, the shuttle frame 3615 further includesone or more travel lanes 310 that allow the shuttles 3605 to travelalong the rack columns 220. In the illustrated example, the shuttleframe 3615 has travel lanes 310 sandwiched between the rack columns 220.The shuttle frame 3615 includes one or more rack access passages 230through which the shuttles 3605 are able to enter or exit the storagerack system 3600. Like in the earlier examples, the travel lanes 310 ofthe shuttle frame 3615 includes one or more rack rails 320 along whichthe shuttles 3605 travel between the racks 3610. The shuttles 3605 areable to independently move along the floor outside of the storage racksystem 3600 so as to transfer items between various external servicelocations and the storage rack system 3600.

At the rack end 222, the storage rack system 3600 has an elevatorsection 3620. Unlike in the earlier examples, the elevator section 3620in the storage rack system 3600 has at least one elevator 3625 thatmoves the shuttle 3605 vertically between the rack levels 225, as isdepicted in FIGS. 36 and 37. The elevator 3625 includes an elevatorplatform 3630 on which the shuttle 3605 is supported during verticalmovement, one or more guide rails 3635 that guide the elevator platform3630, and an elevator drive 3640 that moves the elevator platform 3630vertically along the guide rails 3635. In the illustrated example, theelevator platform 3630 is located between a pair of guide rails 3635,and the elevator platform 3630 is slidably coupled to the guide rails3635. The elevator drive 3640 in the depicted example includes one ormore pulleys that are driven by electric motors, but it is envisionedthat other types of elevator drives can be used such as hydraulic,pneumatic, and/or electromagnetic type drives.

From the floor or ground, the shuttle 3605 is able to move onto and fromthe elevator platform 3630. As can be seen in FIG. 38 as well in theother drawings, the elevator platform 3630 has one or more platformrails 3805 on which the wheel assemblies 715 of the shuttle 3605 ride(FIG. 9). In the depicted example, the elevator platform 3630 includes apair of platform rails 3805 that are located distally away from theracks 3610, but in other examples, the elevator platform 3630 caninclude more or less platform rails 3805 than is shown. Each of theplatform rails 3805 include a ramp section 3810 where the platform rail3805 generally tapers towards the floor or ground. This tapering of theplatform rails 3805 at the ramp sections 3810 allows the shuttle 3605 tosmoothly ride on and off the elevator platform 3630. The platform rails3805 are positioned and spaced to generally match the spacing of therack rails 320 in the travel lanes 310 between the racks 3610.

During operation, the elevator drive 3640 of the elevator 3625 lowersthe elevator platform 3630 to the floor such that the shuttle 3605 isable to move onto the elevator platform 3630. The shuttle 3605 rides upthe ramp sections 3810 onto the platform rails 3805. Once the shuttle3605 is loaded onto the elevator platform 3630, the elevator drive 3640can raise the elevator platform 3630 to the desired rack level 225. Insome case, the elevator platform 3630 is not raised such that theshuttle 3605 is able to service the rack level 225 located along thefloor. Once at the desired rack level 225, the platform rails 3805 ofthe elevator platform 3630 are aligned with the rack rails 320 at therack level 225. The shuttle 3605 is then able to move off the elevatorplatform 3630 and onto the rack rails 320. The shuttle 3605 is then ableto load, unload, and/or otherwise move items to and from the rack 3610along the travel lane 310 in a similar fashion as described before.After performing the designated servicing tasks for a particular racklevel 225, the shuttle 3605 travels back onto the platform rails 3805,and the elevator 3625 can raise or lower the shuttle 3605 to the nextrack level 225 that needs servicing. After the shuttle 3605 performs allof the required tasks for the storage rack system 3600, the elevator3625 lowers the elevator platform 3630 with the shuttle 3605 to thefloor. The shuttle 3605 is then able to exit the elevator 3625 by ridingoff the ramp sections 3810 of the platform rails 3805 and onto thefloor. The shuttle 3605 is then free to move along the floor to performother tasks like delivering and/or retrieving items such as from otherlocations or other storage rack systems 3600.

FIGS. 39, 40, 41, 42, and 43 illustrate a further example of a storagerack system 3900 that can be used in the robotic shuttle system 100 ofFIG. 1. As will be recognized, the storage rack system 3900 sharesseveral components in common with and operates in a similar fashion tothe examples illustrated and described before. For the sake of brevityas well as clarity, these common features will not be again describedbelow in detail, but please refer to the previous discussion. Only thenotable distinctions between the storage rack system 3900 and theexamples described before will be discussed, and unless indicatedotherwise, the storage rack system 3900 in FIG. 39 shares the samecomponents and operates in the same fashion as the examples describedbefore. For example, the storage rack system 3900 includes one or moreshuttles 3605 (FIG. 36), racks 3910, and shuttle frames 3915. Thestorage rack system 3900 will described below as being serviced by theshuttle 3605 shown in FIG. 36, but it should be recognized that othertypes of shuttles 120 can be used.

The storage rack system 3900 includes the rack 3910 on which items arestored, and the shuttle frames 3915 on which the shuttles 3605 are ableto travel along the racks 3910. As shown, each rack 3910 includes aseries of storage rows 215 in which items are stored. The storage rows215 of the rack 3910 extend horizontally to form a series of rackcolumns 220 with rack ends 222. In the illustrated example, the racks3910 extend vertically to form one or more rack levels 225. In otherexamples, the racks 205 can be configured differently such as havingfewer or more storage rows 215, rack columns 220, and/or rack levels225.

The shuttle frame 3915 allows the shuttles 3605 to travel along theracks 3910 and service the various storage rows 215, rack columns 220,and rack levels 225. As shown in FIGS. 39 and 42, the shuttle frame 3915further includes one or more travel lanes 310 that allow the shuttles3605 to travel along the rack columns 220. In the illustrated example,the shuttle frame 3915 has travel lanes 310 sandwiched between the rackcolumns 220. The shuttle frame 3915 includes one or more rack accesspassages 230 through which the shuttles 3605 are able to enter or exitthe storage rack system 3900. Like in the earlier examples, the travellanes 310 of the shuttle frame 3915 include one or more rack rails 320along which the shuttles 3605 travel between the racks 3910. Theshuttles 3605 are able to independently move along the floor outside ofthe storage rack system 3900 so as to transfer items between variousexternal service locations and the storage rack system 3900.

At the rack end 222, the storage rack system 3900 has an elevatorsection 3920. The elevator section 3920 in the storage rack system 3900has at least one elevator 3925 that moves the shuttle 3605 verticallybetween the rack levels 225. The elevator 3925 includes an elevatorplatform 3930 on which the shuttle 3605 is supported during verticalmovement, one or more guide rails 3935 that guide the elevator platform3930, and an elevator drive 3940 that moves the elevator platform 3930vertically along the guide rails 3935. In the illustrated example, theelevator platform 3930 is located between a pair of guide rails 3935,and the elevator platform 3930 is slidably coupled to the guide rails3935. The elevator drive 3940 in the depicted example includes one ormore pulleys that are driven by one or more electric motors 3945, but itis envisioned that other types of elevator drives can be used such ashydraulic, pneumatic, and/or electromagnetic type drives.

At the top in this example, the storage rack system 3900 includes amezzanine 3950 where one or more of the shuttles 3605 can for example bestored, buffered, moved, serviced, and/or sequenced. The elevator 3925has a mezzanine entrance 3955 through where the shuttles 3605 enter andleave the mezzanine 3950. The elevator platform 3930 can raise a shuttle3605 to the mezzanine 3950, and the shuttle 3605 can ride off theelevator platform 3930 onto the mezzanine 3950. In the illustratedexample, the mezzanine 3950 is a generally flat surface on which theshuttles 3605 can move in a similar fashion as when on the floor. Forinstance, the shuttles 3605 can automatically steer and move so as toreshuffle their order before being loaded back onto the elevatorplatform 3930 of the elevator 3925. The mezzanine 3950 allows theshuttle 3605 to be temporarily stored within the storage rack system3900 with minimal interference with other shuttles 3605. With themezzanine 3950, service efficiency can be enhanced by reducing shuttlecongestion in and around the storage rack system 3900. The shuttle 3605does not necessarily have to leave storage rack system 3900 to make roomfor other shuttles 3605. Moreover, the elevator 3925 can be used moreefficiently. The mezzanine 3950 in FIGS. 39, 40, and 41 is illustratedas a single mezzanine 3950 located at the top of the storage rack system3900. In other examples, the storage rack system 3900 can includeseveral mezzanines 3950 located within different rack levels 225 and/orat other locations in the racks 3910.

From the floor or ground, the shuttle 3605 is able to move onto and fromthe elevator platform 3930. As can be seen in FIG. 43 as well in theother drawings, the elevator platform 3930 has one or more platformrails 4305 on which the wheel assemblies 715 of the shuttle 3605 ride(FIG. 9). In the depicted example, the elevator platform 3930 includes apair of platform rails 4305 that are located distally away from theracks 3910, but in other examples, the elevator platform 3930 caninclude more or less platform rails 4305 than is shown. Each of theplatform rails 4305 include a ramp section 4310 where the platform rail4305 generally tapers towards the floor or ground. This tapering of theplatform rails 4305 at the ramp sections 4310 allows the shuttle 3605 tosmoothly ride on and off the elevator platform 3930. The platform rails4305 are positioned and spaced to generally match the spacing of therack rails 320 in the travel lanes 310 between the racks 3910. Theplatform rails 4305 further include one or more retention brackets 4315that help retain the shuttle 3605 as the elevator 3925 moves. Theretention brackets 4315 generally hook the shuttle 3605 when on theelevator 3925.

During operation, the elevator drive 3940 of the elevator 3925 lowersthe elevator platform 3930 to the floor such that the shuttle 3605 isable to move onto the elevator platform 3930. The shuttle 3605 rides upthe ramp sections 4310 onto the platform rails 4305. Once the shuttle3605 is loaded onto the elevator platform 3930, the elevator drive 3940can raise the elevator platform 3930 to the desired rack level 225. Insome case, the elevator platform 3930 is not raised such that theshuttle 3605 is able to service the rack level 225 located along thefloor.

Once at the desired rack level 225, the platform rails 4305 of theelevator platform 3930 are aligned with the rack rails 320 at the racklevel 225. The shuttle 3605 is then able to move off the elevatorplatform 3930 and onto the rack rails 320. The shuttle 3605 is then ableto load, unload, and/or otherwise move items to and from the rack 3910along the travel lane 310 in a similar fashion as described before.After performing the designated servicing tasks for a particular racklevel 225, the shuttle 3605 travels back onto the platform rails 4305,and the elevator 3925 can raise or lower the shuttle 3605 to the nextrack level 225 that needs servicing. As noted before, the elevator 3925can also raise the shuttle 3605 to the mezzanine 3950 so that theshuttle 3605 can for example be buffered. Once the shuttle 3605 is againneeded, the shuttle 3605 can move back onto the elevator platform 3930so as to service other rack levels 225 within the storage rack system3900. After the shuttle 3605 performs all of the required tasks for thestorage rack system 3900, the elevator 3925 lowers the elevator platform3930 with the shuttle 3605 to the floor. The shuttle 3605 is then ableto exit the elevator 3925 by riding off the ramp sections 4310 of theplatform rails 4305 and onto the floor. The shuttle 3605 is then free tomove along the floor to perform other tasks like delivering and/orretrieving items such as from other locations or other storage racksystems 3900.

Glossary of Terms

The language used in the claims and specification is to only have itsplain and ordinary meaning, except as explicitly defined below. Thewords in these definitions are to only have their plain and ordinarymeaning. Such plain and ordinary meaning is inclusive of all consistentdictionary definitions from the most recently published Webster'sdictionaries and Random House dictionaries. As used in the specificationand claims, the following definitions apply to these terms and commonvariations thereof identified below.

“Ambient Energy Source” generally refers to an energy source thatproduces energy using energy from external, natural sources that arepresent in the environment. Some examples of ambient energy include, butare not limited to, solar energy, hydroelectric energy, wind energy,thermal energy and piezoelectric energy.

“Automated Guided Vehicle” (AGV) generally refers to a mobile robot thatis able to automatically self-navigate between various locations. Forexample, AGVs are typically, but not always, able to automaticallynavigate by following markers, such as wires or magnets embedded in thefloor, by using lasers, and/or by using one or more vision systems. AGVsare also typically, but not always, designed to automatically avoidcollisions, such as with other AGVs, equipment, and personnel. AGVs arecommonly, but not always, used in industrial applications to movematerials around a manufacturing facility or warehouse.

“Buffering System” generally refers to a mechanism that is used to storeitems and/or storage containers on a temporary or near-temporary basis.In one form, the buffering system includes one or more storage racksthat are arranged to store items and/or storage containers both in avertical and horizontal arrangement. The rows of shelves in the rackscan be arranged in a generally uniform manner so as to form a repeatingpattern of shelves or in a non-uniform manner. The height or spacing ofshelves can be the same on all rows or levels of shelves or different.The shelves in one example include conveyors for indexing the itemsand/or storage containers.

“Chassis” generally refers to an internal frame and/or supportingstructure that supports an external object, body, and/or housing of thevehicle and/or electronic device. In one form, the chassis can furtherprovide protection for internal parts of the vehicle and/or electronicdevice. By way of non-limiting examples, a chassis can include theunderpart of a vehicle, including the frame on which the body ismounted. In an electronic device, the chassis for example includes aframe and/or other internal supporting structure on which one or morecircuit boards and/or other electronics are mounted.

“Computer” generally refers to any computing device configured tocompute a result from any number of input values or variables. Acomputer may include a processor for performing calculations to processinput or output. A computer may include a memory for storing values tobe processed by the processor, or for storing the results of previousprocessing.

A computer may also be configured to accept input and output from a widearray of input and output devices for receiving or sending values. Suchdevices include other computers, keyboards, mice, visual displays,printers, industrial equipment, and systems or machinery of all typesand sizes. For example, a computer can control a network interface toperform various network communications upon request. The networkinterface may be part of the computer, or characterized as separate andremote from the computer.

A computer may be a single, physical, computing device such as a desktopcomputer, a laptop computer, or may be composed of multiple devices ofthe same type such as a group of servers operating as one device in anetworked cluster, or a heterogeneous combination of different computingdevices operating as one computer and linked together by a communicationnetwork. The communication network connected to the computer may also beconnected to a wider network such as the Internet. Thus, a computer mayinclude one or more physical processors or other computing devices orcircuitry, and may also include any suitable type of memory.

A computer may also be a virtual computing platform having an unknown orfluctuating number of physical processors and memories or memorydevices. A computer may thus be physically located in one geographicallocation or physically spread across several widely scattered locationswith multiple processors linked together by a communication network tooperate as a single computer.

The concept of “computer” and “processor” within a computer or computingdevice also encompasses any such processor or computing device servingto make calculations or comparisons as part of disclosed system.Processing operations related to threshold comparisons, rulescomparisons, calculations, and the like occurring in a computer mayoccur, for example, on separate servers, the same server with separateprocessors, or on a virtual computing environment having an unknownnumber of physical processors as described above.

A computer may be optionally coupled to one or more visual displaysand/or may include an integrated visual display. Likewise, displays maybe of the same type, or a heterogeneous combination of different visualdevices. A computer may also include one or more operator input devicessuch as a keyboard, mouse, touch screen, laser or infrared pointingdevice, or gyroscopic pointing device to name just a few representativeexamples. Also, besides a display, one or more other output devices maybe included such as a printer, plotter, industrial manufacturingmachine, 3D printer, and the like. As such, various display, input andoutput device arrangements are possible.

Multiple computers or computing devices may be configured to communicatewith one another or with other devices over wired or wirelesscommunication links to form a communication network. Networkcommunications may pass through various computers operating as networkappliances such as switches, routers, firewalls or other network devicesor interfaces before passing over other larger computer networks such asthe internet. Communications can also be passed over the communicationnetwork as wireless data transmissions carried over electromagneticwaves through transmission lines or free space. Such communicationsinclude using WiFi or other Wireless Local Area Network (WLAN) or acellular transmitter/receiver to transfer data. Such signals conform toany of a number of wireless or mobile telecommunications technologystandards such as 802.11a/b/g/n, 3G, 4G, and the like.

“Container” generally refers to an object creating a partially or fullyenclosed space that can be used to contain, store, and transportobjects, items, and/or materials. In other words, a container caninclude an object that can be used to hold or transport something. Byway of non-limiting examples, containers can include boxes, cartons,plastic packaging, totes, bags, jars, envelopes, barrels, cans, bottles,drums, and/or packages.

“Container Transfer Mechanism”, “Tray Transfer Table”, or “TransferTable” generally refers to a system configured to transfer storagecontainers, such as trays, totes, and the like, between a shuttle andstorage rack. In one example, the container transfer mechanism isincorporated into the shuttle, but in other examples, all or part of thecontainer transfer mechanism is incorporated into the rack. In one form,the container transfer mechanism includes a lift mechanism with anextendable conveyor that is able to extend into the rack to retrieve orplace the storage container in the rack.

“Controller” generally refers to a device, using mechanical, hydraulic,pneumatic electronic techniques, and/or a microprocessor or computer,which monitors and physically alters the operating conditions of a givendynamical system. In one nonlimiting example, the controller can includean Allen Bradley brand Programmable Logic Controller (PLC). A controllermay include a processor for performing calculations to process input oroutput. A controller may include a memory for storing values to beprocessed by the processor or for storing the results of previousprocessing. A controller may also be configured to accept input andoutput from a wide array of input and output devices for receiving orsending values. Such devices include other computers, keyboards, mice,visual displays, printers, industrial equipment, and systems ormachinery of all types and sizes. For example, a controller can controla network or network interface to perform various network communicationsupon request. The network interface may be part of the controller, orcharacterized as separate and remote from the controller. A controllermay be a single, physical, computing device such as a desktop computeror a laptop computer, or may be composed of multiple devices of the sametype such as a group of servers operating as one device in a networkedcluster, or a heterogeneous combination of different computing devicesoperating as one controller and linked together by a communicationnetwork. The communication network connected to the controller may alsobe connected to a wider network such as the Internet. Thus a controllermay include one or more physical processors or other computing devicesor circuitry and may also include any suitable type of memory. Acontroller may also be a virtual computing platform having an unknown orfluctuating number of physical processors and memories or memorydevices. A controller may thus be physically located in one geographicallocation or physically spread across several widely scattered locationswith multiple processors linked together by a communication network tooperate as a single controller. Multiple controllers or computingdevices may be configured to communicate with one another or with otherdevices over wired or wireless communication links to form a network.Network communications may pass through various controllers operating asnetwork appliances such as switches, routers, firewalls or other networkdevices or interfaces before passing over other larger computer networkssuch as the Internet. Communications can also be passed over the networkas wireless data transmissions carried over electromagnetic wavesthrough transmission lines or free space. Such communications includeusing WiFi or other Wireless Local Area Network (WLAN) or a cellulartransmitter/receiver to transfer data.

“Conveyor” is used in a broad sense to generally refer to a mechanismthat is used to transport something, like an item, box, container,and/or SKU. By way of nonlimiting examples, the conveyor can includebelt conveyors, wire mesh conveyors, chain conveyors, electric trackconveyors, roller conveyors, cross-belt conveyors, vibrating conveyors,and skate wheel conveyors, to name just a few. The conveyor all or inpart can be powered or unpowered. For instance, sections of theconveyors can include gravity feed sections.

“Elastic” generally refers to a solid material and/or object that iscapable of recovering size and/or shape after deformation. Elasticmaterial typically is capable of being easily stretched, expanded,and/or otherwise deformed, and once the deforming force is removed, theelastic material returns to its original shape. By way of non-limitingexamples, elastic materials include elastomers and shape memorymaterials. For instance, elastic materials can include rubber, bothnatural and synthetic, and plastics.

“Electric Motor” generally refers to an electrical machine that convertselectrical energy into mechanical energy. Normally, but not always,electric motors operate through the interaction between one or moremagnetic fields in the motor and winding currents to generate force inthe form of rotation. Electric motors can be powered by direct current(DC) sources, such as from batteries, motor vehicles, and/or rectifiers,or by alternating current (AC) sources, such as a power grid, inverters,and/or electrical generators. An electric generator can (but not always)be mechanically identical to an electric motor, but operates in thereverse direction, accepting mechanical energy and converting themechanical energy into electrical energy.

“Elevator” generally refers to a type of transportation device thatmoves people, goods, items, and/or other objects in a vertical directionbetween floors, levels, decks, and/or other structures. In onenonlimiting example, the elevator includes a platform and/or cage thatis raised and lowered mechanically in a vertical shaft. Drives formoving the elevator can include hydraulic, pneumatic, and/orelectromagnetic type drives.

“End of Arm Tool” (EoAT) or “End Effector” generally refers to a deviceat the end of the robotic arm that is designed to interact with theenvironment. The nature of this interaction of the device with theenvironment depends on the application of the robotic arm. The EoAT canfor instance interact with an SKU or other environmental objects in anumber of ways. For example, the EoAT can include one or more grippers,such as impactive, ingressive, astrictive, and/or contiguitive typegrippers. Grippers typically, but not always, use some type ofmechanical force to grip objects. However, other types of interactions,such as those based on suction or magnetic force, can be used to securethe object to the EoAT. By way of non-limiting examples, the EoAT canalternatively or additionally include vacuum cups, electromagnets,Bernoulli grippers, electrostatic grippers, van der Waals grippers,capillary grippers, cryogenic grippers, ultrasonic grippers, and lasergrippers, to name just a few.

“Energy Source” generally refers to a device, structure, mechanism,and/or system that provides power for performing work. The energysupplied by the energy source can take many forms including electrical,chemical, electrochemical, nuclear, hydraulic, pneumatic, gravitational,kinetic, and/or potential energy forms. The energy source for instancecan include ambient energy sources, such as solar panels, externalenergy sources, such as from electrical power transmission networks,and/or portable energy sources, such as batteries. The energy source caninclude an energy carrier containing energy that can be later convertedto other forms, such as into mechanical, heat, electrical, and/orchemical forms. Energy carriers can for instance include springs,electrical batteries, capacitors, pressurized air, dammed water,hydrogen, petroleum, coal, wood, and/or natural gas, to name just a few.

“Energy Storage System” (ESS) or “Energy Storage Unit” generally refersto a device that captures energy produced at one time for use at a latertime. The energy can be supplied to the ESS in one or more forms, forexample including radiation, chemical, gravitational potential,electrical potential, electricity, elevated temperature, latent heat,and kinetic types of energy. The ESS converts the energy from forms thatare difficult to store to more conveniently and/or economically storableforms. By way of non-limiting examples, techniques for accumulating theenergy in the ESS can include: mechanical capturing techniques, such ascompressed air storage, flywheels, gravitational potential energydevices, springs, and hydraulic accumulators; electrical and/orelectromagnetic capturing techniques, such as using capacitors, supercapacitors, and superconducting magnetic energy storage coils;biological techniques, such as using glycogen, biofuel, and starchstorage mediums; electrochemical capturing techniques, such as usingflow batteries, rechargeable batteries, and ultra batteries; thermalcapture techniques, such as using eutectic systems, molten salt storage,phase-change materials, and steam accumulators; and/or chemical capturetechniques, such as using hydrated salts, hydrogen, and hydrogenperoxide. Common ESS examples include lithium-ion batteries and supercapacitors.

“Extended Position” generally refers to a location or state of amechanism where at least a portion is stretched out to be longer orbigger. When in the extended position, the mechanism does not need to bestretched to the fullest extent possible (i.e., fully extended), butinstead, it can be partly lengthened or enlarged (i.e., partiallyextended).

“Fin Gripper”, “Shark Fin Gripper”, or “Shark Fin Finger” generallyrefer to an A-frame shaped robotic finger that is flexible to securelygrip a wide variety of objects, including fragile and/or irregularlyshaped objects. The fin gripper is configured to act in a fashionsimilar to how a fish fin bends. The gripper fin includes flange membersjoined together at an acute angle to form a V shape, and the flanges areconnected together by a series of spaced apart cross beams or bands tofrom a triangle. Typically, the fin gripper is made all or in part ofdeformable and/or elastic material that allows the fin gripper to bend,but portions of the fin gripper can include hard material. Pushing onone side of the V shape causes the fin gripper to deform and a tipportion of the fin gripper is able to bend around the gripped object. Inother words, the fin gripper is able to adapt to the shape of a workpiece when pressure is applied laterally. When the fin gripper has asymmetrical shape about a central axis, the fin gripper is able to bendin either lateral direction. On the other hand, when the fin gripper hasan asymmetrical shape, the fin gripper tends to bend in only onedirection.

“Frame” generally refers to a structure that forms part of an object andgives strength and/or shape to the object.

“Gearbox” or “Transmission” generally refer to a power system thatprovides controlled application of mechanical power. The gearbox usesgears and/or gear trains to provide speed, direction, and/or torqueconversions from a rotating power source to another device.

“Guidance, Navigation, and Control (GNC) System” generally refers to aphysical device, a virtual device, and/or a group of devices configuredto control the movement of vehicles, such as automobiles, automatedguided vehicles, ships, aircraft, drones, spacecraft, and/or othermoving objects. GNC systems are typically configured to determine adesired path of travel or trajectory of the vehicle from the vehicle'scurrent location to a designated target, as well as desired changes invelocity, rotation, and/or acceleration for following the path. The GNCsystem can include and/or communicate with sensors like compasses, GPSreceivers, Loran-C, star trackers, inertial measurement units,altimeters, environmental sensors, and the like. At a given time, suchas when the vehicle is travelling, the GNC system is configured todetermine the location (in one, two, or three dimensions) and velocityof the vehicle. For example, the GNC system is able to calculate changesin position, velocity, attitude, and/or rotation rates of a movingvehicle required to follow a certain trajectory and/or attitude profilebased on information about the state of motion of the vehicle. The GNCsystem is able to maintain or change movement of the vehicle bymanipulating forces by way of vehicle actuators, such as steeringmechanisms, thrusters, flaps, etc., to guide the vehicle whilemaintaining vehicle stability. GNC systems can be found in autonomous orsemi-autonomous vehicles.

“Lateral” generally refers to being situated on, directed toward, orcoming from the side.

“Lift Mechanism” or “Lifting Mechanism” generally refers to anymechanical device designed to raise and/or lower objects in a generallyvertical direction. By way of non-limiting examples, the lift mechanismcan include rotating joints, elevators, screw drives, and/or linkagetype devices. The lift mechanism can be designed to discretely liftobjects, such as in a case of an elevator, or lift objects in acontinuous manner, such as chain and bucket type elevators and/or screwtype conveyors. The lift mechanism can be manually and/or automaticallypowered. For instance, the lift mechanism can be powered by electricity,pneumatics, and/or hydraulics.

“Longitudinal” generally relates to length or lengthwise dimension of anobject, rather than across.

“Memory” generally refers to any storage system or device configured toretain data or information. Each memory may include one or more types ofsolid-state electronic memory, magnetic memory, or optical memory, justto name a few. Memory may use any suitable storage technology, orcombination of storage technologies, and may be volatile, nonvolatile,or a hybrid combination of volatile and nonvolatile varieties. By way ofnon-limiting example, each memory may include solid-state electronicRandom Access Memory (RAM), Sequentially Accessible Memory (SAM) (suchas the First-In, First-Out (FIFO) variety or the Last-In-First-Out(LIFO) variety), Programmable Read Only Memory (PROM), ElectronicallyProgrammable Read Only Memory (EPROM), or Electrically ErasableProgrammable Read Only Memory (EEPROM).

Memory can refer to Dynamic Random Access Memory (DRAM) or any variants,including static random access memory (SRAM), Burst SRAM or Synch BurstSRAM (BSRAM), Fast Page Mode DRAM (FPM DRAM), Enhanced DRAM (EDRAM),Extended Data Output RAM (EDO RAM), Extended Data Output DRAM (EDODRAM), Burst Extended Data Output DRAM (BEDO DRAM), Single Data RateSynchronous DRAM (SDR SDRAM), Double Data Rate SDRAM (DDR SDRAM), DirectRambus DRAM (DRDRAM), or Extreme Data Rate DRAM (XDR DRAM).

Memory can also refer to non-volatile storage technologies such asNon-Volatile Read Access memory (NVRAM), flash memory, non-volatileStatic RAM (nvSRAM), Ferroelectric RAM (FeRAM), Magnetoresistive RAM(MRAM), Phase-change memory (PRAM), Conductive-Bridging RAM (CBRAM),Silicon-Oxide-Nitride-Oxide-Silicon (SONOS), Resistive RAM (RRAM),Domain Wall Memory (DWM) or “Racetrack” memory, Nano-RAM (NRAM), orMillipede memory. Other nonvolatile types of memory include optical discmemory (such as a DVD or CD ROM), a magnetically encoded hard disc orhard disc platter, floppy disc, tape, or cartridge media. The concept ofa “memory” includes the use of any suitable storage technology or anycombination of storage technologies.

“Motor” generally refers to a machine that supplies motive power for adevice with moving parts. The motor can include rotor and linear typemotors. The motor can be powered in any number of ways, such as viaelectricity, internal combustion, pneumatics, and/or hydraulic powersources. By way of non-limiting examples, the motor can include aservomotor, a pneumatic motor, a hydraulic motor, a steam engine,pneumatic piston, hydraulic piston, and/or an internal combustionengine.

“Network” or “Computer Network” generally refers to a telecommunicationsnetwork that allows computers to exchange data. Computers can pass datato each other along data connections by transforming data into acollection of datagrams or packets. The connections between computersand the network may be established using either cables, optical fibers,or via electromagnetic transmissions such as for wireless networkdevices.

Computers coupled to a network may be referred to as “nodes” or as“hosts” and may originate, broadcast, route, or accept data from thenetwork. Nodes can include any computing device such as personalcomputers, phones, and servers as well as specialized computers thatoperate to maintain the flow of data across the network, referred to as“network devices”. Two nodes can be considered “networked together” whenone device is able to exchange information with another device, whetheror not they have a direct connection to each other.

Examples of wired network connections may include Digital SubscriberLines (DSL), coaxial cable lines, or optical fiber lines. The wirelessconnections may include BLUETOOTH®, Worldwide Interoperability forMicrowave Access (WiMAX), infrared channel or satellite band, or anywireless local area network (Wi-Fi) such as those implemented using theInstitute of Electrical and Electronics Engineers' (IEEE) 802.11standards (e.g. 802.11(a), 802.11(b), 802.11(g), or 802.11(n) to name afew). Wireless links may also include or use any cellular networkstandards used to communicate among mobile devices including 1G, 2G, 3G,or 4G. The network standards may qualify as 1G, 2G, etc. by fulfilling aspecification or standards such as the specifications maintained by theInternational Telecommunication Union (ITU). For example, a network maybe referred to as a “3G network” if it meets the criteria in theInternational Mobile Telecommunications-2000 (IMT-2000) specificationregardless of what it may otherwise be referred to. A network may bereferred to as a “4G network” if it meets the requirements of theInternational Mobile Telecommunications Advanced (IMTAdvanced)specification. Examples of cellular network or other wireless standardsinclude AMPS, GSM, GPRS, UMTS, LTE, LTE Advanced, Mobile WiMAX, andWiMAX-Advanced.

Cellular network standards may use various channel access methods suchas FDMA, TDMA, CDMA, or SDMA. Different types of data may be transmittedvia different links and standards, or the same types of data may betransmitted via different links and standards.

The geographical scope of the network may vary widely. Examples includea Body Area Network (BAN), a Personal Area Network (PAN), a Local-AreaNetwork (LAN), a Metropolitan Area Network (MAN), a Wide Area Network(WAN), or the Internet.

A network may have any suitable network topology defining the number anduse of the network connections. The network topology may be of anysuitable form and may include point-to-point, bus, star, ring, mesh, ortree. A network may be an overlay network which is virtual and isconfigured as one or more layers that use or “lay on top of” othernetworks.

A network may utilize different communication protocols or messagingtechniques including layers or stacks of protocols. Examples include theEthernet protocol, the internet protocol suite (TCP/IP), the ATM(Asynchronous Transfer Mode) technique, the SONET (Synchronous OpticalNetworking) protocol, or the SDE1 (Synchronous Digital Elierarchy)protocol. The TCP/IP internet protocol suite may include the applicationlayer, transport layer, internet layer (including, e.g., IPv6), or linklayer.

“Pinion” generally refers to a relatively small gear in a gear drivetrain. Typically, but not always, the smaller pinion engages or isengaged inside a larger gear or to a rack. When engaging a rack,rotational motion applied to the pinion causes the rack to move relativeto the pinion, thereby translating the rotational motion of the pinioninto linear motion. By way of non-limiting examples, the pinion can beincorporated into differential, rack-and-pinion, and clutch bell drivetrains, to name just a few. The pinion can be oriented in a number ofmanners relative to the larger gear or rack. For instance, the pinioncan be angled perpendicular to a crown gear in a differential typedrive.

“Powertrain” or “Powerplant” generally refers to devices and/or systemsused to transform stored energy into kinetic energy for propulsionpurposes. The powertrain can include multiple power sources and can beused in non-wheel-based vehicles. By way of nonlimiting examples, thestored energy sources can include chemical, solar, nuclear, electrical,electrochemical, kinetic, and/or other potential energy sources. Forexample, the powertrain in a motor vehicle includes the devices thatgenerate power and deliver the power to the road surface, water, and/orair. These devices in the powertrain include engines, motors,transmissions, drive shafts, differentials, and final drive components(e.g., drive wheels, continuous tracks, propeller, thrusters, etc.).

“Processor” generally refers to one or more electronic componentsconfigured to operate as a single unit configured or programmed toprocess input to generate an output. Alternatively, when of amulti-component form, a processor may have one or more componentslocated remotely relative to the others. One or more components of eachprocessor may be of the electronic variety defining digital circuitry,analog circuitry, or both. In one example, each processor is of aconventional, integrated circuit microprocessor arrangement, such as oneor more PENTIUM, i3, i5 or i7 processors supplied by INTEL Corporationof 2200 Mission College Boulevard, Santa Clara, Calif. 95052, USA. Inanother example, the processor uses a Reduced Instruction Set Computing(RISC) architecture, such as an Advanced RISC Machine (ARM) typeprocessor developed and licensed by ARM Holdings of Cambridge, UnitedKingdom. In still yet other examples, the processor can include aCentral Processing Unit (CPU) and/or an Accelerated Processing Unit(APU), such as those using a K8, K10, Bulldozer, Bobcat, Jaguar, and Zenseries architectures, supplied by Advanced Micro Devices, Inc. (AMD) ofSanta Clara, Calif.

Another example of a processor is an Application-Specific IntegratedCircuit (ASIC). An ASIC is an Integrated Circuit (IC) customized toperform a specific series of logical operations for controlling thecomputer to perform specific tasks or functions. An ASIC is an exampleof a processor for a special purpose computer, rather than a processorconfigured for general-purpose use. An application-specific integratedcircuit generally is not reprogrammable to perform other functions andmay be programmed once when it is manufactured.

In another example, a processor may be of the “field programmable” type.Such processors may be programmed multiple times “in the field” toperform various specialized or general functions after they aremanufactured. A field-programmable processor may include aField-Programmable Gate Array (FPGA) in an integrated circuit in theprocessor. FPGA may be programmed to perform a specific series ofinstructions which may be retained in nonvolatile memory cells in theFPGA. The FPGA may be configured by a customer or a designer using aHardware Description Language (HDL). An FPGA may be reprogrammed usinganother computer to reconfigure the FPGA to implement a new set ofcommands or operating instructions. Such an operation may be executed inany suitable means such as by a firmware upgrade to the processorcircuitry.

Just as the concept of a computer is not limited to a single physicaldevice in a single location, so also the concept of a “processor” is notlimited to a single physical logic circuit or package of circuits butincludes one or more such circuits or circuit packages possiblycontained within or across multiple computers in numerous physicallocations. In a virtual computing environment, an unknown number ofphysical processors may be actively processing data, and the unknownnumber may automatically change over time as well.

The concept of a “processor” includes a device configured or programmedto make threshold comparisons, rules comparisons, calculations, orperform logical operations applying a rule to data yielding a logicalresult (e.g. “true” or “false”). Processing activities may occur inmultiple single processors on separate servers, on multiple processorsin a single server with separate processors, or on multiple processorsphysically remote from one another in separate computing devices.

“Retracted Position” generally refers to a location or state of amechanism where it is withdrawn back to have a shorter length or asmaller size. When in the retracted position, the mechanism is typicallyshorter or smaller than when in the extended position.

“Robotic Arm” or “Robot Arm” generally refers to a type of mechanicalarm, usually programmable, with similar functions to a human arm. Linksof the robot arm are connected by joints allowing either rotationalmotion (such as in an articulated robot) or translational (linear)displacement. The robot arm can have multiple axes of movement. By wayof nonlimiting examples, the robot arm can be a 4, 5, 6, or 7 axis robotarm. Of course, the robot arm can have more or less axes of movement orfreedom. Typically, but not always, the end of the robot arm includes amanipulator that is called an “End of Arm Tool” (EoAT) for holding,manipulating, or otherwise interacting with the cargo items or otherobjects. The EoAT can be configured in many forms besides what is shownand described herein.

“Sensor” generally refers to an object whose purpose is to detect eventsand/or changes in the environment of the sensor, and then provide acorresponding output. Sensors include transducers that provide varioustypes of output, such as electrical and/or optical signals. By way ofnonlimiting examples, the sensors can include pressure sensors,ultrasonic sensors, humidity sensors, gas sensors, motion sensors,acceleration sensors, displacement sensors, force sensors, opticalsensors, and/or electromagnetic sensors. In some examples, the sensorsinclude barcode readers, RFID readers, and/or vision systems.

“Shuttle” generally refers to a mechanism or device that is able totransport one or more items that are resting on and/or in the device.Each shuttle is capable to move independently of one another and is ableto move in multiple directions (e.g., horizontally, vertically,diagonally, etc.) along a shuttle frame. In one example, the shuttleincludes a power train that is configured to move the shuttle, asteering system to direct shuttle movement, a tote transfer mechanismwith a lift mechanism, and a robotic arm configured to transfer items toand/or from the shuttle. The power train in one example includes wheelsthat are driven by an electric motor, but in other examples, the powertrain can be configured differently. For instance, the power train caninclude a hydraulic motor and/or a pneumatic motor.

“Shuttle Frame” generally refers to a structure along where the shuttlemoves. In one non-limiting example, shuttle frame allows the shuttles tomove independently of one another. The shuttle frame can extendvertically and/or horizontally to allow shuttle movement in multipledirections (e.g., horizontally, vertically, diagonally, etc.) along theshuttle frame. In one example, the shuttle frame includes multiplevertical levels and lanes. Typically, but not always, the shuttle frameis generally aligned with one or more racks to allow the shuttle toservice the racks. A shuttle frame in certain examples includes one ormore rails on which the shuttle travels. The shuttle frame can furtherinclude vertical elevator shafts for facilitating vertical movement ofthe shuttle and one or more switches for guiding the direction of theshuttle onto different rails. The shuttle frame in one form includesmultiple horizontal travel lanes where the shuttle can travelhorizontally along the ends of racks and/or between opposing racks. Thetravel lanes can further include intersections where the shuttle is ableto turn and travel in different horizontal and/or vertical directions.The shuttle frame in further examples include rack access passages,entrance/exit travel lanes, doorways, or docks through which theshuttles are able to enter and/or exit the shuttle frame and travelalong a floor or other surface.

“Shuttle System” generally refers to a mechanism used to transport itemsvia one or more shuttles that move along a shuttle frame. The shuttlesin the shuttle system are able to at least move in two spatialdirections (i.e., in a vertical direction and a horizontal direction)along the shuttle frame. In another form, the shuttle is able to move inall three spatial dimensions within the shuttle frame. The shuttlesystem can include an infeed shuttle system that typically (but notalways) supplies items to a buffering system. The shuttle system canfurther include a discharge shuttle system that typically (but notalways) discharges items from the buffering system.

“Steering System” generally refers to one or more devices and/orlinkages that allow a vehicle to follow a desired course. By way ofnon-limiting examples, the steering system can include active, passive,rear wheel, front wheel, four-wheel, power, steer-by-wire, articulated,speed sensitive, differential, crab, hydraulic, rack and pinion, wormand sector, recirculating ball, Ackerman, and/or Bell-crank typesystems, to name just a few.

“Stock Keeping Unit” (SKU) or “Item” generally refers to an individualarticle or thing. The SKU can come in any form and can be packaged orunpackaged. For instance, SKUs can be packaged in cases, cartons, bags,drums, containers, bottles, cans, pallets, and/or sacks, to name just afew examples. The SKU is not limited to a particular state of mattersuch that the item can normally have a solid, liquid, and/or gaseousform for example.

“Storage Container” generally refers to an object that can be used tohold or transport SKUs or other objects. By way of nonlimiting examples,the storage container can include cartons, totes, pallets, bags, and/orboxes.

“Storage Facility” generally refers to a location for keeping and/orstoring items or goods. A storage facility may keep the items or goodsindoors or outdoors. As an example, a storage facility may be a largebuilding, such as a warehouse, or may be an outdoor area that is eitheropen or enclosed by a fence or by another suitable method.

“Storage Rack” or “Rack” generally refer to a framework structure onwhich items and/or storage containers are arranged, housed, stored,deposited, and/or removed. The framework can include one or more tieredvertical levels formed by bars, shelves, conveyors, wires, and/or pegson which the items and/or storage containers are supported. Theframework can have different overall shapes. For instance, the frameworkcan have a rectangular or box shape in one example, and in otherexamples, the framework can include an A-Frame type rack. The locationof the levels and rows in the rack can be fixed and/or adjustable.

“Transceiver” generally refers to a device that includes both atransmitter and a receiver that share common circuitry and/or a singlehousing. Transceivers are typically, but not always, designed totransmit and receive electronic signals, such as analog and/or digitalradio signals.

“Vacuum Cup” generally refers to a device or object made of elastic,flexible material having a surface that uses negative air pressure(i.e., a partial vacuum or suction) to adhere to a non-porous object.

“Vision System” generally refers to one or more devices that collectdata and form one or more images by a computer and/or other electronicsto determine an appropriate position and/or to “see” an object. Thevision system typically, but not always, includes an imaging-system thatincorporates hardware and software to generally emulate functions of aneye, such as for automatic inspection and robotic guidance. In somecases, the vision system can employ one or more video cameras,Analog-to-Digital Conversion (ADC), and Digital Signal Processing (DSP)systems. By way of a non-limiting example, the vision system can includea charge-coupled device for inputting one or more images that are passedonto a processor for image processing. A vision system is generally notlimited to just the visible spectrum. Some vision systems image theenvironment at infrared (IR), visible, ultraviolet (UV), and/or X-raywavelengths. In some cases, vision systems can interpretthree-dimensional surfaces, such as through binocular cameras.

“Web” generally refers to a material made of a network of thread,strings, cords, and/or wires that form openings in-between. In one form,the cords are interlaced or woven together. The interlaced pattern canbe uniform or random.

“Wireless Power Transfer” (WPT) or “Wireless Energy Transmission” (WET)generally refers to the transmission of electrical energy without wiresas a physical link. In a WPT system, a power transmitter, driven byelectric power from a power source, generates a time-varyingelectromagnetic field, which transmits power across space to a powerreceiver, which extracts power from the field and supplies the power toan electrical load. WPT is typically useful to power electrical deviceswhere interconnecting wires are inconvenient, hazardous, and/or are notpossible. For example, WPT can be used to charge portable electricalloads, like smartphones and vehicles. WPT techniques mainly fall intotwo general categories, non-radiative and radiative techniques. In nearfield or non-radiative techniques, power is transferred over shortdistances by magnetic fields using inductive coupling between coils ofwire, or by electric fields using capacitive coupling between metalelectrodes. Inductive charging can be for example used to chargehandheld devices like phones and electric toothbrushes, RFID tags, andwirelessly charging implantable medical devices like artificial cardiacpacemakers, or electric vehicles. In far-field or radiative techniques,also called power beaming, power is transferred by beams ofelectromagnetic radiation, like microwaves and/or laser beams. Thesefar-field techniques can transport energy longer distances, but the beamgenerally should be aimed at or near the power receiver. By way ofnonlimiting examples, solar power satellites and wireless powered droneaircraft can be powered via these far-field WPT techniques.

It should be noted that the singular forms “a,” “an,” “the,” and thelike as used in the description and/or the claims include the pluralforms unless expressly discussed otherwise. For example, if thespecification and/or claims refer to “a device” or “the device”, itincludes one or more of such devices.

It should be noted that directional terms, such as “up,” “down,” “top,”“bottom,” “lateral,” “longitudinal,” “radial,” “circumferential,”“horizontal,” “vertical,” etc., are used herein solely for theconvenience of the reader in order to aid in the reader's understandingof the illustrated embodiments, and it is not the intent that the use ofthese directional terms in any manner limit the described, illustrated,and/or claimed features to a specific direction and/or orientation.

While the invention has been illustrated and described in detail in thedrawings and foregoing description, the same is to be considered asillustrative and not restrictive in character, it being understood thatonly the preferred embodiment has been shown and described and that allchanges, equivalents, and modifications that come within the spirit ofthe inventions defined by the following claims are desired to beprotected. All publications, patents, and patent applications cited inthis specification are herein incorporated by reference as if eachindividual publication, patent, or patent application were specificallyand individually indicated to be incorporated by reference and set forthin its entirety herein.

The term “or” is inclusive, meaning “and/or”.

Reference Numbers 100 robotic shuttle system 110 storage rack system 120shuttle 130 control system 140 network 205 rack 210 shuttle frame 215storage rows 220 rack columns 222 rack end 225 rack levels 230 rackaccess passage 305 elevator section 310 travel lane 315 intersections320 rack rails 325 turn rails 330 access rails 505 elevator rails 510rack sections 515 transition rails 520 shuttle switch 525 turntable 530curved track section 535 straight track section 540 rail channels 545turn shoulder 605 robot arm 610 container transfer mechanism 615powertrain 620 GNC system 622 energy source 625 processor 630 memory 635communication system 640 sensor 705 chassis 710 body 715 wheel assembly718 wheel well 720 container holder 725 holder wall 730 container cavity735 rack container platform 740 extendable conveyor 745 End of Arm Tool900 shuttle 905 robot arm 910 End of Arm Tool 915 containers 920 tray925 tote 1005 shark fin finger 1010 hub 1015 extendable palm vacuum cup1020 grip pads 1025 vacuum ports 1030 tip vacuum cup 1105 shuttlecontroller 1110 lift cavity 1300 lift mechanism 1305 base 1310 platformsupport frame 1315 scissor linkage assembly 1320 actuator motor 1325platform cavity 1605 drive wheel 1610 pinion 1615 pinion teeth 1705mounting bracket 1708 steering system 1710 steering collar 1715 fixedsection 1720 rotating section 1725 steering motor 1730 wheel bracket1735 drive motor 1737 gearbox 1740 drive shaft 1745 brake system 1750brake disc 1755 brake caliper system 1760 pinion bearing 1900 WPT system1905 charge storage device 1910 charge control device 1915 electricalconnection flow path 1920 electrical connection 2000 containers 2005separator system 2010 separator web 2015 opening 2020 web opening 2025elastic bands 2030 web slot 2035 skid pad 2105 item 2205 arrow 2305shuttle frame level 2310 arrow 2315 arrow 2405 arrow 2410 arrow 2505arrow 2605 arrow 2610 target storage row 2615 L-bracket 2705 arrow 2805upward direction 2810 extension direction 2905 retraction direction 3005downward direction 3405 arrow 3505 arrow 3600 storage rack system 3605shuttle 3610 rack 3615 shuttle frame 3620 elevator section 3625 elevator3630 elevator platform 3635 guide rails 3640 elevator drive 3805platform rails 3810 ramp section 3900 storage rack system 3910 rack 3915shuttle frame 3920 elevator section 3925 elevator 3930 elevator platform3935 guide rails 3940 elevator drive 3945 electric motor 3950 mezzanine3955 mezzanine entrance 4305 platform rails 4310 ramp section 4315retention brackets

What is claimed is:
 1. A robotic shuttle system, comprising: a racksystem including one or more racks configured to store one or moreitems; a shuttle configured to move along the racks in the rack system;and wherein the shuttle includes a robot arm configured to move theitems between the racks and the shuttle.
 2. The robotic shuttle systemof claim 1, wherein the rack system includes a shuttle frame where theshuttle travels along the racks.
 3. The robotic shuttle system of claim2, wherein the shuttle is configured to move independently outside ofthe rack system.
 4. The robotic shuttle system of claim 3, wherein theshuttle includes one or more steerable wheels that are powered by theshuttle.
 5. The robotic shuttle system of claim 4, wherein the wheelseach include a pinion and a drive wheel.
 6. The robotic shuttle systemof claim 5, wherein the shuttle frame includes a vertical elevator railwith teeth configured to engage the pinion.
 7. The robotic shuttlesystem of claim 6, further comprising a shuttle switch configured tochange movement of the shuttle between vertical and horizontal movement.8. The robotic shuttle system of claim 7, wherein the shuttle switchincludes a turntable with a straight track located between opposingcurved tracks.
 9. The robotic shuttle system of claim 5, wherein theshuttle frame includes an intersection where the shuttle turnshorizontally with the wheels.
 10. The robotic shuttle system of claim 9,wherein the intersection includes one or more rail channels with turnshoulders in which the drive wheel is received.
 11. The robotic shuttlesystem of claim 4, wherein the shuttle includes an Energy Storage System(ESS).
 12. The robotic shuttle system of claim 11, wherein the wheelsare configured to form an electrical circuit with rails to charge theESS.
 13. The robotic shuttle system of claim 1, wherein the shuttle hasa container holder and a rack container platform.
 14. The roboticshuttle system of claim 13, wherein the rack container platform has alift mechanism configured to move the rack container platformvertically.
 15. The robotic shuttle system of claim 14, wherein the rackcontainer platform has an extendable conveyor configured to extend to anextended position in the racks.
 16. The robotic shuttle system of claim1, wherein the shuttle includes an extendable belt conveyor configuredto extend to an extended position.
 17. The robotic shuttle system ofclaim 1, wherein the shuttle includes a lift mechanism configured tovertically move a rack container platform.
 18. The robotic shuttlesystem of claim 17, wherein the lift mechanism is configured to raisethe rack container platform above the shuttle.
 19. The robotic shuttlesystem of claim 17, wherein the lift mechanism is configured to lowerthe rack container platform below the shuttle.
 20. The robotic shuttlesystem of claim 17, wherein the lift mechanism is configured to move therack container platform above and below the shuttle.
 21. The roboticshuttle system of claim 1, wherein the robot arm includes an End of ArmTool (EoAT) with a shark fin finger to grip the items.
 22. The roboticshuttle system of claim 21, wherein the shark fin finger includes a tipvacuum cup.
 23. The robotic shuttle system of claim 21, wherein theshark fin finger includes a grip pad with one or more vacuum ports. 24.The robotic shuttle system of claim 21, wherein the EoAT includes anextendable palm vacuum cup that is configured to extend from the EoAT.25. The robotic shuttle system of claim 1, further comprising a totewith an internal separator supported on the shuttle.
 26. The roboticshuttle system of claim 25, wherein the internal separator includes amonolayer web configured to separate the items.
 27. The robotic shuttlesystem of claim 26, wherein the monolayer web includes a grid of elasticbands.
 28. The robotic shuttle system of claim 27, wherein the grid hasa perpendicular array of the elastic bands to separate the items. 29.The robotic shuttle system of claim 25, wherein the shuttle isconfigured to map position of the items in the tote for blind picking.30. The robotic shuttle system of claim 25, wherein the tote isconfigured to store multiple different kinds of Stock Keeping Units(SKUs).
 31. The robotic shuttle system of claim 25, wherein the internalseparator is configured to hold a uniform array of the items with thesame Stock Keeping Unit (SKU).
 32. The robotic shuttle system of claim25, wherein the shuttle includes a vision system for picking denserandom storage of the items in the tote.
 33. The robotic shuttle systemof claim 1, wherein the rack system includes an elevator with anelevator platform configured to vertically move the shuttle.
 34. Therobotic shuttle system of claim 33, wherein the elevator platformincludes one or more rails that support the shuttle.
 35. The roboticshuttle system of claim 34, wherein the rails have a ramped section thatis tapered for loading the shuttle onto the elevator platform.
 36. Therobotic shuttle system of claim 33, wherein the elevator platformincludes one or more retention brackets configured to retain theshuttle.
 37. The robotic shuttle system of claim 33, wherein the racksystem includes a mezzanine and the elevator has a mezzanine entrance totransfer the shuttle to and from the mezzanine.
 38. A method,comprising: moving a shuttle on a floor, wherein the shuttle includes arobotic arm; entering a rack system that includes one or more racksconfigured to store one or more items at a storage location with theshuttle, wherein the rack system includes a shuttle frame; moving theshuttle along the shuttle frame within the rack system to the storagelocation; and conveying the items between the storage location and theshuttle with the robotic arm.
 39. The method of claim 38, wherein saidmoving the shuttle along the shuttle frame includes moving the shuttlein a vertical direction.
 40. The method of claim 39, wherein said movingthe shuttle in the vertical direction includes moving the shuttle alongan elevator rail that extends in the vertical direction.
 41. The methodof claim 39, wherein said moving the shuttle in the vertical directionincludes moving the shuttle with an elevator platform of an elevator.42. The method of claim 38, wherein said moving the shuttle along theshuttle frame includes turning the shuttle in a horizontal direction byturning one or more wheels of the shuttle in one or more turn shouldersof the shuttle frame.
 43. The method of claim 38, further comprisingbuffering the shuttle on a mezzanine in the rack system.